Chevrolet - Blazer 4wd - Workshop Manual - 2003 - 2003

Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the air cleaner outlet duct. 2. Partially drain the cooling system. 3. Remove the radiator inlet hose from the radiator support. 4. Using the J 38185, reposition the radiator inlet hose clamp from the radiator. 5. Reposition the radiator inlet hose from the radiator. 6. Using the J 38185, reposition the radiator inlet hose clamp from the coolant outlet. 7. Reposition the radiator inlet hose from the coolant outlet. 8. Remove the radiator inlet hose. Installation Procedure Page 8190 Trim Panel: Service and Repair Garnish Molding Replacement - Sunroof Panel Window (ZRX/EXTREME w/ CF5) Garnish Molding Replacement - Sunroof Panel Window (ZRX/EXTREME w/ CF5) Removal Procedure 1. With a medium flat-bladed tool, remove the service cover. 2. Remove the motor/actuator trim cover screw (2). 3. Lower the motor/actuator trim cover and remove the sunroof switch (4) from the cover (5). Page 550 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 5278 C304 (Body Harness To LR Door Harness) (4-Door) Page 9701 Conversion English/Metric Part 1 Page 3249 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 9126 Abbreviations And Meanings - Part 4 Page 5248 C203 (Body Harness To IP Harness) Part 3 Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 6326 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 879 Steps 1-3 Page 6806 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR System. Refer to SIR Disabling and Enabling Zone 3. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel nut. 4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment during installation. 5. Remove the steering wheel from the steering shaft. 6. On vehicles with a tilt column, pull the tilt lever straight out from the steering column. 7. Remove the tilt lever assembly. 8. Remove 2 TORX(R) head screws (1) from the lower shroud (2). Page 3072 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Page 5380 Splice Pack SP202 Page 800 Abbreviations And Meanings - Part 9 Page 4966 Page 5864 Disclaimer Page 9457 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 1070 1. Install the power steering gear return hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering gear return hose to the power steering gear. Tighten the power steering gear return hose to the power steering gear to 30 Nm (22 ft. lbs.). 3. Connect the wiring harness clip to the power steering return hose at the power steering gear. 4. Connect the power steering gear return hose to the power steering cooler, if equipped. Tighten the power steering gear return hose to the power steering cooler clamp to 2 Nm (18 inch lbs.). 5. Connect the power steering gear return hose to the power steering pump (for vehicles without a power steering cooler). Tighten the power steering hose clamp to 2 Nm (18 inch lbs.). 6. Remove the drain pan from under the vehicle. 7. Install the air cleaner assembly. 8. Bleed the power steering system. Page 2572 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 5193 Relay Block - Body Part 3 Page 9138 Abbreviations And Meanings - Part 16 Page 5378 Splice Pack SP201 Part 1 Locations SIR Components Locations Electronic Components Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 5020 Abbreviations And Meanings - Part 9 Locations Power Seat Switch: Locations Seat Switches Specifications Valve Guide: Specifications Valves - Valve Stem Oil Seal Installed Height ............................................................................................................... 1 - 2 mm (0.03937 - 0.07874 inch) Valves - Valve Stem-to-Guide Clearance - Intake - Production ............................................................................ 0.025 - 0.069 mm (0.0010 - 0.0027 inch) Valves Valve Stem-to-Guide Clearance - Intake - Service ................................................................................. 0.025 - 0.094 mm (0.0010 - 0.0037 inch) Valves - Valve Stem-to-Guide Clearance - Exhaust - Production ......................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch) Valves Valve Stem-to-Guide Clearance - Exhaust - Service .............................................................................. 0.025 - 0.094 mm (0.0010 - 0.0037 inch) Page 16 Disclaimer Page 636 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement REMOVAL PROCEDURE IMPORTANT: An 8 digit part identification number is stamped on the bottom of the throttle body casting. Refer to this number if servicing or part replacement is required. 1. Disconnect the negative battery cable. 2. Remove the air cleaner outlet duct. 3. Remove the air cleaner adapter stud. 4. Disconnect the cruise control cable from the throttle body. Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch - Driver (Utility, Crew Cab W/ RKE) Page 2601 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the powertrain control module (PCM) or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing/replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Move the PCM retention bar and retainer away from the PCM. 3. Remove the PCM from the PCM mounting bracket. Page 4428 Page 5009 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 3497 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 6434 Air Door Actuator / Motor: Service and Repair Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Push up on the J-spring in order to release the storage compartment door. 2. Firmly pull rearward to release the recirculation actuator (2) locking tab. 3. Remove the actuator rod from the recirculation door (1) by pushing the actuator up and to the left. IMPORTANT: The air inlet door is behind the air distribution duct. 4. Disconnect the vacuum connector from the recirculation actuator (2). 5. Remove the recirculation actuator (2). INSTALLATION PROCEDURE 1. Install the recirculation actuator (2). 2. Connect the vacuum connector to the recirculation actuator (2). 3. Install the actuator rod to the recirculation door (1) by placing the hole in the actuator rod over the hook on the recirculation door lever. 4. Align the recirculation actuator with the recirculation door assembly and firmly push forward to engage the recirculation actuator locking tab. 5. Push up on the J-spring in order to return the storage compartment door to the normal position. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 8979 Conversion English/Metric Part 1 Page 7377 Page 8184 Use the J 38778 in order to remove the windshield garnish molding from the windshield pillar. Pull the molding away from the pillar and then up. INSTALLATION PROCEDURE Install the windshield molding to the windshield pillar. Align the retainer clips with the slots and press the molding into place. Garnish Molding Sunroof Panel Window RPO ZRX/Extreme W/CF5 GARNISH MOLDING REPLACEMENT - SUNROOF PANEL WINDOW WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. With a medium flat-bladed tool, remove the service cover. Page 2550 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 4830 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster (charged) battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster (charged) battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed (leave the hazard flashers ON). 2.5. Turn OFF the ignition switch. 3. Attach the end of 1 jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 4. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 5. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative booster cable to the housings of other vehicle electrical accessories or equipment. The current flow during jump starting may damage such equipment. 6. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1500 RPM. 7. Crank the engine of the vehicle with the battery. If the engine does not crank or cranks too slowly, perform the following steps: 7.1. Turn the ignition OFF. 7.2. Allow the booster vehicle engine to run at approximately 1500 RPM for 5 minutes. 7.3. Attempt to start the engine of the vehicle with the discharged battery. Diagrams Page 4975 Page 1590 Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seal. The exhaust valve oil stem seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal, or the material may be red in color (2) with no paint stripe. The intake valve oil seal is black in color. 1. Assemble the valve into the proper valve guide. 2. Select the proper valve stem oil seal for the specific valve guide. 3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil. 4. Assemble the valve stem oil seal onto the valve stem. Caution: Refer to Safety Glasses Caution in Service Precautions. 5. Using the J 42073, install the valve stem oil seal onto the valve guide. 5.1. Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat. 5.2. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. There should be a 1 - 2 mm (0.03937 - 0.07874 inch) gap between the bottom edge of the valve stem oil seal and the valve guide. 6. Install the valve spring (3). 7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Electronic Brake Control Module (EBCM) Connector C1 Page 7371 Emblem/Nameplate Replacement (Chevrolet) Body Emblem: Service and Repair Emblem/Nameplate Replacement (Chevrolet) Emblem/Nameplate Replacement (Chevrolet) Tools Required * J 25070 Heat Gun * J 41409 Body Molding Removal Tool Removal Procedure 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070. Apply heat using a circular motion for about 30 seconds. 3. Use a J 41409 to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the emblem/nameplate will be installed. Page 2800 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the powertrain control module (PCM) or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing/replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Move the PCM retention bar and retainer away from the PCM. 3. Remove the PCM from the PCM mounting bracket. Page 233 Door Lock Cylinder Switch - Driver (w/o RKE) Page 3329 Ignition Coil: Description and Operation IGNITION COIL AND ICM The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Locations Ignition Coil, Ignition Control Module (ICM), Manifold Absolute Pressure (MAP) Sensor, Throttle Body, And EVAP Canister Purge Solenoid Page 5779 C500 (Body Harness To LF Door Harness) (W/ Power Locks/Windows) Part 3 Page 6488 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 511 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Page 8120 7. Install the cup holder insert. 8. Install the shift control lever. Console Replacement - Front Floor (Non-Full Length) Console Replacement - Front Floor (Non-Full Length) Removal Procedure 1. For manual transmission only, remove the shift control lever. Refer to Control Lever and/or Boot Replacement in Manual Transmission - NV 1500 or to Control Lever and/or Boot Replacement in Manual Transmission - NV 3500. 2. Remove the console from the floor. Pull up on the console in order to release the retainer clips. Installation Procedure 1. Use care when installing the console so the clips do not bend. 2. install the console to the floor. 3. For manual transmission only, install the shift lever. Refer to Control Lever and/or Boot Replacement in Manual Transmission - NV 1500 or to Control Lever and/or Boot Replacement in Manual Transmission - NV 3500. Console Replacement - Overhead (Full Length) Console Replacement - Overhead (Full Length) Removal Procedure 1. Remove the overhead lamp lens on the overhead console. 2. Remove the 3 overhead console roof screws. One screw is located towards the front of the console and the other 2 are located behind the dome lamp lens. 3. Disconnect the electrical connectors. 4. Remove the console. Installation Procedure Page 9477 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7265 Conversion English/Metric Part 1 Page 3662 For vehicles repaired under warranty, use the table. Disclaimer Page 3991 Park Neutral Position (PNP) Switch Page 3419 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 4528 7. Slowly tighten the C-clamp until the piston is fully seated in the caliper bore. 8. Remove the C-clamp from the brake caliper. 9. Remove the brake caliper assembly from the mounting bracket. 10. Using denatured alcohol, clean the Make pads and related parts. 11. Using non-lubricated, filtered compressed air, dry the brake pads and related parts. 12. Remove the rear brake pads. Important: DO NOT reuse the rear brake pad anti/rattle spring. Used the NEW brake pad anti/rattle spring. 13. Remove the rear brake pad anti/raffle spring from the brake caliper. Page 9404 Abbreviations And Meanings - Part 17 Page 8340 WA805K/62 - WA810K/48 Page 3177 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Service and Repair Tailgate Weatherstrip: Service and Repair Weatherstrip Replacement - End Gate Window Removal Procedure 1. Open the endgate. 2. Starting at the corner of the endgate flange, pull the weatherstrip molding from the endgate. Installation Procedure 1. Push the ends of the weatherstrip onto the endgate flange corners. 2. Push the weatherstrip molding onto the flange along the entire length of the endgate. Page 2520 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 4036 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Page 1077 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the J 38185 reposition the radiator outlet hose clamp from the radiator. 3. Using the J 38185 reposition the radiator outlet hose clamp from the water pump. 4. Remove the radiator outlet hose. Installation Procedure Page 5678 C211 (Steering Column Harness To Body Harness) Part 3 Page 6890 Disclaimer Air Temperature Actuator Air Door Actuator / Motor: Service and Repair Air Temperature Actuator AIR TEMPERATURE ACTUATOR REPLACEMENT REMOVAL PROCEDURE The air temperature actuator is located on the top right hand side of the HVAC module. 1. Remove the instrument panel carrier. 2. Disconnect the electrical connector (2). 3. Remove the air temperature actuator retaining screws. 4. Remove the air temperature actuator from the HVAC module. INSTALLATION PROCEDURE Page 5517 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 9602 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 6056 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 2792 Powertrain Control Module (PCM) Connector C2 Part 2 Page 6461 Page 8924 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Page 9804 Arrows And Symbols Uses various symbols in order to describe different service operations Page 7427 Diagnostic Tips Review Table Page 4877 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 6523 Abbreviations And Meanings - Part 24 Locations Power Seat Switch: Locations Seat Switches Page 9982 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Service and Repair Trunk / Liftgate Handle: Service and Repair Pullstrap Replacement - Lift Gate Removal Procedure 1. Remove the screw that retains the liftgate assist handle to the liftgate trim panel. 2. Carefully pry at the edge of the liftgate assist handle in order to remove the liftgate assist handle from the liftgate trim panel. Installation Procedure 1. Install the liftgate assist handle to the liftgate trim panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw that retains the liftgate assist handle to the liftgate trim panel. Tighten the screw to 1.9 N.m (17 lb in). Page 870 Page 1117 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. .................................................... Synchromesh Fluid Page 9810 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 7676 Abbreviations And Meanings - Part 4 Page 2652 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 7789 3. Install the screws that retains the outside door handle to the door panel. Tighten the screws to 4 N.m (35 lb in). 4. Install the outside door lock rod to the handle (2). 5. Install the outside door handle rod to the handle (1). 6. Install the outside door handle screw access hole plug. 7. Install the water deflector. 8. Install the door trim panel. Page 9865 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 710 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 3727 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 3176 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 882 Steps 9-12 Page 6230 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Page 5746 C211 (Steering Column Harness To Body Harness) Part 4 Page 7119 Abbreviations And Meanings - Part 12 Page 5187 Fuse Block - Underhood Connector C4 Part 3 Page 4631 7. Remove the caliper from the caliper anchor bracket. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol. 2. Dry the brake caliper pin bolts using non lubricated, compressed filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper bolts. 4. DO NOT apply the lubricant to the brake pad hardware. 5. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. Page 6529 Registered And Non-Registered Trademarks - Part 3 Page 2648 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1635 Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. 1. Remove the drive belt. 2. Position a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 3. Move the drive belt tensioner through its full travel. ^ The movement should feel smooth. ^ There should be no binding. ^ The tensioner should return freely. 4. If any binding is observed, replace the drive belt tensioner. 5. Install the drive belt. Page 9581 A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 478 Page 2051 3. Install the heater outlet hose to the water pump. 4. Install the heater outlet hose clamp using the J 38185 at the water pump. 5. Install the heater inlet hose to the intake manifold fitting. 6. Install the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 7. Install the outlet heater hose to the heater core. 8. Install the outlet heater hose clamp using the J 38185 at the heater core. 9. Install the heater outlet hose to the retaining clip at the engine water outlet. 10. Place the outlet heater hose in the retaining clip above the right side valve cover. 11. Close the retaining clip. Ensure that the clip locks. Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Specifications Rocker Arm Assembly: Specifications Valve Rocker Arm Bolt ........................................................................................................................ .................................................... 30 Nm (22 ft. lbs.) Valve Rocker Arm Cover Bolt ............................................................................................................................................................ 12 Nm (106 inch lbs.) Rocker Arms - Valve Rocker Arm Ratio ........................................................... ............................................................................................................ 1.5:1 Locations Steering Column Components Page 5996 9. Remove the power steering pump filler neck tube mounting bolt. 10. Remove the power steering pump filler neck tube. 11. Remove the power steering rear mounting bracket nut from the engine stud. 12. Remove the power steering pump front mounting bolts. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Locations Steering Column Components Diagrams Power Mirror Switch: Diagrams Outside Rearview Folding Mirror Switch (Export) Page 2983 4. Connect the purge solenoid electrical connector. 5. Connect the EVAP purge pipe. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Page 7061 Page 6893 4. Remove the bolt that retains the passenger-side seat belt buckle or buckle and belt assembly to the seat. 5. Remove the passenger-side seat belt buckle or buckle and belt assembly from the seat. INSTALLATION PROCEDURE 1. Install the passenger-side seat belt buckle or buckle and belt assembly to the vehicle. 2. Install the bolt that retains the passenger-side seat belt buckle or buckle and belt assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle or buckle and belt assembly bolt to 70 N.m (52 lb ft). Page 8648 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Locations Vehicle Speed Sensor: Locations Manual Transmission, LH Page 9189 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Page 517 Intake Air Temperature Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. Intake Air Temperature (IAT) Sensor 3. Remove the IAT sensor by pulling straight out using a rotating motion. INSTALLATION PROCEDURE Page 5763 C310 (Sunroof Jumper Harness To Sunroof Harness) (ZRX/Extreme With RPO Code CF5) Page 4672 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front (Dual Piston Caliper) Brake Hose Replacement - Front (Dual Piston Caliper) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. 3. Clean all dirt and other foreign material from the brake hoses and brake pipe fitting. 4. Using a backup wrench on the brake pipe fitting, disconnect the brake pipe fitting from the brake hose fitting. 5. Disconnect the brake pipe fitting at the frame. 6. Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent fluid loss and contamination. 7. Remove the brake pipe retainer. 8. Remove the brake hose retainer nut and bolt from the upper control arm. 9. Remove the front brake hose bolt and gaskets from the caliper. 10. Remove the front brake hose. 11. Remove the metal gaskets from the brake hose bolt. The metal gaskets may be stuck to the brake caliper and/or the brake hose end. Installation Procedure Important: DO NOT reuse the old metal gaskets (copper), replace them with NEW metal (copper) gaskets. Page 5250 C203 (Body Harness To IP Harness) Part 5 Page 567 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 8193 6. Position the sunroof switch (4) to the motor/actuator trim cover (5). 7. Locate switch to cover in order to secure. 8. Position motor/actuator trim cover to the sunroof panel window garnish molding. 9. Install the motor/actuator trim cover screw (2). Tighten the screw to 1.5 N.m (13 lb in). 10. Install the motor/actuator service cover. Page 345 Front Frame Grounds Page 3621 Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin 12. Remove the spacer plate support. 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following defects: Page 1225 Fuse Block - Underhood Connector C4 Part 1 Page 1451 3. Remove the rotor. 4. Remove the wheel stud from the axle flange using the J 43631. Installation Procedure 1. Install the stud into the axle flange. 2. Install the 4 washers and the lug nut to the stud 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the rotor. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Page 7980 Liftglass/Endgate Lock Cylinder Switch Page 6705 12. Install the A/C refrigerant filter (1) to the evaporator tube with the flow arrow pointing towards the evaporator. 13. Install the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nuts to.................15 N.m (11 lb ft). 14. Remove the nuts (4) from the A/C refrigerant filter (1). 15. Coat the O-ring seals (3) with 525 viscosity refrigerant oil. 16. Install the O-rings (3) to the evaporator tube. 17. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to.........................15 N.m (11 lb ft). 18. Install accumulator (4) to the evaporator (3). 19. Tighten the accumulator nut at the evaporator. Tighten Tighten the nut to..........................15 N.m (11 lb ft). 20. Position the accumulator bracket 60 mm (2.36 in) toward the high side access port. 21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 22. Leak test the fittings component using the J 39400-A. 23. Install the engine coolant reservoir. 24. Install the PCM. Page 8633 Page 6072 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4198 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. .................................................... Synchromesh Fluid Page 5537 Abbreviations And Meanings - Part 16 Page 9705 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 5598 Fuse Block - Underhood Connector C3 Part 3 Page 9673 Page 9846 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 9847 Power Window Switch: Connector Views Door Lock And Window Switch - Driver C1 Part 1 Page 829 Window Switch - LR Page 5024 Abbreviations And Meanings - Part 13 Page 3972 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Page 7104 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 1134 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 6456 Page 7108 Abbreviations And Meanings - Part 1 Page 7430 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 3098 Steps 6-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Page 3409 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 8861 1. Install the center vent grille panel to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that secure the center vent grille panel to the cowl. Tighten the screws to 1.5 N.m (13 lb in). 3. Install the push-pin retainers securing the center vent grille panel to the cowl. 4. Install the right and the left vent grille end panels to the cowl. Tighten the screws to 1.5 N.m (13 lb in). 5. Install the screws securing the securing the right and the left vent grille ends to the cowl. 6. Install the windshield wiper arms. Page 1449 Wheel Fastener: Service and Repair Rear (Rear Drum Brakes) Wheel Stud Replacement (Rear Drum Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the brake drum. 4. Remove the wheel stud from the axle flange using J43631. Installation Procedure OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 2473 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 3607 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 5274 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 2 Page 4997 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 9577 Page 1377 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554, US ACDELCO 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Page 2692 Abbreviations And Meanings - Part 12 Page 9981 Wiper Blade: Service and Repair Wiper Blade Element Replacement WIPER BLADE ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Page 5130 Abbreviations And Meanings - Part 23 Page 5696 C310 (Sunroof Jumper Harness To Sunroof Harness) (ZRX/Extreme With RPO Code CF5) Page 7493 Speaker Replacement Reference Page 947 Distributor: Service and Repair Distributor Inspection 1. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 1.1. Remove the cap. 1.2. Place 1 lead from the DMM on a cap terminal. 1.3. Use the other lead in order to probe all other terminals and the center carbon ball. 1.4. Move the base lead to the next terminal. Probe all other leads. 1.5. Continue this procedure until you test all the secondary terminals. 1.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 3. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 4. Inspect the shaft for shaft-to-bushing looseness: 4.1. Inspect the housing for cracks or damage. 4.2. Insert the shaft in the housing. 4.3. If the shaft wobbles, replace the housing assembly. Page 5375 Splice Pack SP101 OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5136 Registered And Non-Registered Trademarks - Part 2 Page 2958 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 157 Body Control Module (BCM) C1 Part 2 Page 985 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 2. Remove the drive belt. 3. Slowly release the tension on the drive belt tensioner arm. Installation Procedure 1. Route the drive belt over all the pulleys except the drive belt tensioner pulley. 2. Observe the drive belt routing for the vehicles without air conditioning. Page 5899 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 2199 Engine Coolant Temperature (ECT) Sensor Seat Belt Buckle Replacement - Front Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Front REMOVAL PROCEDURE 1. Disconnect the driver-side seat belt buckle electrical connector. 2. Remove the bolt that retains the driver-side seat belt buckle or buckles to the seat. 3. Remove the driver-side seat belt buckle or buckles from the seat. Page 5109 Abbreviations And Meanings - Part 2 Page 973 engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 526 Knock Sensor (KS) Page 6140 6. Install the grease fittings. 7. Lubricate the upper ball joint. 8. Connect the wheel speed sensor electrical connector. 9. Install the wheel speed sensor electrical connector to the upper control arm. 10. Install the brake caliper. 11. Install tire and wheel assembly. 12. Lower the vehicle. 13. Check the front wheel alignment. Page 9015 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 4749 8. Install the park brake cable to the park brake lever. 9. Adjust the park brake shoe (1). 10. Install the rear brake rotor. Page 4985 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Locations Electronic Components Page 3349 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Locations Left Hand Side Of Instrument Panel Page 6175 2. Remove the stabilizer shaft link upper mounting bolt and nut. 3. Remove the stabilizer shaft link lower mounting nut. 4. Remove the stabilizer shaft link. Installation Procedure 1. Install the stabilizer shaft link. 2. Install the stabilizer shaft link lower mounting nut. 3. Install the stabilizer shaft link upper mounting bolt and nut. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the stabilizer shaft link mounting nuts. ^ Tighten the stabilizer shaft link lower mounting nut to 68 Nm (50 ft. lbs.). ^ Tighten the stabilizer shaft link upper mounting nut to 35 Nm (25 ft. lbs.). 5. Lower the vehicle. Page 5152 Application Table Part 2 Page 9236 Page 9095 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Power Steering Cooler Pipe/Hose Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Power Steering Cooler Pipe/Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the air cleaner assembly. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering cooler hose from the power steering pump. 4. Disconnect the power steering cooler hose from the power steering cooler. 5. Remove the power steering cooler hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Page 8867 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Door Opening Weatherstrip Replacement - Door Opening Removal Procedure 1. Remove the door opening weatherstrip from the door opening. 2. Gently pull the weatherstrip from the pinch weld flange. Installation Procedure 1. Install the door opening weatherstrip to the door opening. 2. Position the pre-formed corner of the weatherstrip in the upper rear corner of the door opening. 3. Push the weatherstrip onto the pinch weld flange. Start at the pre-formed corner and work around the entire edge of the door opening. Service and Repair Brake Adjuster: Service and Repair Adjusting Screw Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the brake shoe return springs. 5. Remove the brake shoe guide. 6. Remove the hold down springs. 7. Remove the hold down pins. 8. Remove the actuator lever and the actuator lever pivot. 9. Remove the actuator lever and the lever pivot. 10. Remove the lever return spring. Page 5252 C203 (Body Harness To IP Harness) Part 7 Page 6350 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 5619 Application Table Part 4 Body Relay Block Page 678 Park Neutral Position (PNP) Switch Page 7440 Page 5975 Power Steering Line/Hose: Service and Repair Power Steering Pressure Hose Power Steering Pressure Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the steering linkage shield, if equipped. 3. Install a drain pan under the vehicle. 4. Disconnect the pressure hose from the power steering pump. 5. Lower the vehicle. 6. Remove the air cleaner assembly. 7. Disconnect the power steering gear pressure hose from the power steering gear. 8. Remove the power steering gear pressure hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 878 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 2697 Abbreviations And Meanings - Part 17 Diagrams Headlamp Washer Fluid Pump (Export) Page 756 Page 2645 Page 5045 Starter Motor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the differential carrier shield mounting bolts, if equipped. 4. Remove the differential carrier shield, if equipped. 5. Remove the starter mounting bolts. Page 2592 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C2 Powertrain Control Module (PCM) Connector C2 Part 1 Page 4442 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Specifications Compressor Clutch: Specifications CLUTCH GAP Information not supplied by the manufacturer. Page 3020 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 9786 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 6070 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 5195 Relay Block - Body Part 5 Page 8592 5. Remove the recliner assembly from the seat. INSTALLATION PROCEDURE 1. Install the recliner assembly to the seat. 2. Install the recliner assembly to the seat frame bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the recliner assembly to the seat frame bolts to 24 N.m (18 lb ft). 3. Install the inertia latch. 4. Install the recliner trim cover to the seat. 5. Install the recliner handle. Seat Back Release Cable Replacement - Front SEAT BACK RELEASE CABLE REPLACEMENT - FRONT REMOVAL PROCEDURE Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 7275 Abbreviations And Meanings - Part 1 Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Page 1924 Spark Plug: Service and Repair SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 2900 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 9008 Abbreviations And Meanings - Part 20 Page 2317 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 2961 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 9050 Compass: Service and Repair Electronic Compass Module Replacement ELECTRONIC COMPASS MODULE REPLACEMENT REMOVAL PROCEDURE Due to the complexity of the compass system and the extent of outside influences on the compass' performance, thoroughly inspect the system prior to performing repairs. Inspect the compass in an area that is free from potential interference such as in an open field. Inspect that the compass is calibrated in order to verify the existence of a problem. 1. Remove the overhead console. 2. Remove the compass sensor from the overhead console. INSTALLATION PROCEDURE 1. Install the compass sensor to the overhead console. 2. Install the overhead console. 3. Calibrate the compass. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 2638 Specifications Valve Spring: Specifications Valve Springs - Valve Spring Free Length ............................................................................................................................................ 51.3 mm (2.02 inch) Valve Springs - Valve Spring Installed Height - Intake ............................................................................................ 42.92 - 43.43 mm (1.670 - 1.700 inch) Valve Springs - Valve Spring Installed Height - Exhaust ......................................................................................... 42.92 - 43.43 mm (1.670 - 1.700 inch) Valve Springs - Valve Spring Load - Closed .................................................................................................... 338 - 374 N 43.2 mm (76 - 84 lb 1.70 inch) Valve Springs - Valve Spring Load - Open ................................................................................................... 832 - 903 N 32.3 mm (187 - 203 lb 1.27 inch) Page 923 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 4787 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Page 3339 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector (3). 2. Remove 2 screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 3. Remove the ignition control module and heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the 2 screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). Page 8410 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Disconnect the memory seat module harness connectors. 3. Remove the 2 screws securing the memory module bracket to the seat adjuster frame. 4. Remove the memory module bracket with the module. 5. Remove the module from the bracket. INSTALLATION PROCEDURE IP Fuse Block Details Fuse Block: Application and ID IP Fuse Block Details Location View Application Table Part 1 Page 4508 3. Remove the pistons (2) from the caliper bores. 4. Remove the boots (1) from the caliper bores. Do not scratch the caliper bores. 5. Remove the piston seals (3) from the caliper bores. Do not use a metal tool. 6. Remove the bleeder valve cap (4). 7. Remove the bleeder valve (5) from the caliper housing (6). 8. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Replace the pistons or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore Use a crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Assembly Procedure 1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid. 2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves. 3. Install the boot seals (1) on the pistons (2). 4. Install the pistons in the caliper bores. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the bleeder valve (5) in the caliper housing (6). Tighten the bleeder valve to 7 Nm (62 inch lbs.). 6. Install the bleeder valve cap (4). Page 3154 1. Install the new O-ring seals on the engine compartment fuel feed and the return pipes. 2. Connect the chassis fuel feed and return pipes (1) to the engine compartment fuel feed and return pipes. 3. Install the fuel pipes into the retainer clip (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fuel pipe retainer clip bolt. Tighten 1. Tighten the fuel pipe fittings to 27 N.m (20 lb ft) using a back-up wrench. 2. Tighten the fuel pipe retainer clip bolt to 30 N.m (22 lb ft). 3. Connect the fuel feed pipe (3) and the fuel return pipe (2). 4. Install the transmission. 5. Tighten the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 1428 Disclaimer Page 9703 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 2325 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 3032 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 5112 Abbreviations And Meanings - Part 5 Page 8879 Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Seal Replacement - Hood Rear Removal Procedure 1. Remove the screws securing the seal to the cowl. 2. Use a flat-bladed tool in order to carefully break the adhesive bond. 3. Remove the seal from the cowl plenum flange. 4. Clean the flange. Use a suitable solvent such as a mixture of 50 percent isopropyl alcohol and 50 percent water or high-flash naptha. 5. Dry the area thoroughly. Installation Procedure 1. Remove the liner from the adhesive strip. 2. Position the seal to the cowl plenum. 3. Press the seal into place. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws to secure the seal to the cowl. Tighten the cowl plenum seal screws to 1.9 N.m (17 lb in). Page 8941 Page 3995 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Upper Control Arm Bushings Replacement Control Arm Bushing: Service and Repair Upper Control Arm Bushings Replacement Upper Control Arm Bushings Replacement ^ Tools Required J 21474-01 Control Arm Bushing Service Set - J 22269-01 Accumulator and Servo Piston Remover Removal Procedure 1. Remove the upper control arm from the vehicle. 2. Install the upper control arm in a vise. 3. Remove the washers and the nuts from upper control arm shaft. 4. Remove the upper control arm bushings. Use the J 22269-01 and J 21474-5. 5. Remove the upper control arm shaft from the upper control arm. Installation Procedure Page 9475 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 5793 Splice Pack SP201 Part 2 Page 8706 Abbreviations And Meanings - Part 26 Page 6405 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 2894 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 1105 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 8196 Use the J 38778 in order to remove the windshield garnish molding from the windshield pillar. Pull the molding away from the pillar and then up. INSTALLATION PROCEDURE Install the windshield molding to the windshield pillar. Align the retainer clips with the slots and press the molding into place. Garnish Molding Sunroof Panel Window RPO ZRX/Extreme W/CF5 GARNISH MOLDING REPLACEMENT - SUNROOF PANEL WINDOW WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. With a medium flat-bladed tool, remove the service cover. Page 5733 C203 (Body Harness To IP Harness) Part 7 Page 6005 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. Page 2772 Body Control Module (BCM) C2 Part 2 Page 9794 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 5539 Abbreviations And Meanings - Part 18 Page 9796 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2618 Steps 1-2 A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Page 5070 Page 1678 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil into a suitable container. 3. For 2WD vehicles, remove the oil filter from the oil filter adapter. 4. For Four-Wheel Drive vehicles, open the access panel in the steering linkage shield. 5. Remove the oil filter from the remote oil filter adapter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Page 813 Abbreviations And Meanings - Part 22 Page 8331 WA526F/72 - WA528F/76 Page 9824 Abbreviations And Meanings - Part 10 Page 2948 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 5815 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 7696 Abbreviations And Meanings - Part 24 Page 2400 Steps 9-12 Page 7123 Abbreviations And Meanings - Part 16 Page 4568 1. Remove the brake caliper. 2. Remove the brake pads. 3. Remove the brake caliper mount. 4. Remove and dispose of the sheet metal rotor retainers. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 9130 Abbreviations And Meanings - Part 8 Page 8948 Filler Tube Replacement (2-Door) Fuel Filler Hose: Service and Repair Filler Tube Replacement (2-Door) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Raise the vehicle. 4. Wipe the vent hose connection at the fuel tank and then disconnect the vent hose and clamp (1). 5. Wipe the fuel filler hose connection at the fuel tank and then disconnect the fuel filler hose and clamp (2). 6. Remove the filler pipe ground strap bolt (4). 7. Remove the fuel fill pipe to fill pipe housing attaching screws. 8. Remove the fuel fill and vent pipes and hoses. Page 4670 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front (Single Piston Caliper) Brake Hose Replacement - Front (Single Piston Caliper) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front tires and wheels assembly. 3. Clean all dirt and foreign material from the brake hoses and the brake pipes. 4. Using a backup wrench on the brake pipe fitting, disconnect the brake pipe from the brake hose. Important: Install a plug or cap in the brake pipe to the exposed brake pipe fitting end in order to prevent fluid loss and contamination. 5. Disconnect the brake pipe fitting from the flex brake hose at the frame. 6. Remove the front brake hose retainer at the frame bracket. 7. Remove the hose front flex brake hose bolt and gaskets from the brake caliper. 8. Remove the brake hose from the brake caliper. 9. Remove the copper gaskets from the brake hose bolt. These gaskets maybe stick to the brake caliper or the brake hose bolt. Installation Procedure Important: DO NOT reuse the old copper gaskets. Always use NEW copper gaskets. 1. Install the NEW copper gaskets on the brake hose bolt. Notice: Refer to Fastener Notice in Service Precautions. Page 164 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry, any door opened, the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch, door jamb switch - Passenger door latch, door jamb switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(tm) data from the Passlock(tm) sensor. If the Passlock(tm) data is correct, the BCM will pass theft. The BCM will then transmit the code password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(tm) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(tm) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Page 808 Abbreviations And Meanings - Part 17 Page 5660 C203 (Body Harness To IP Harness) Part 1 Page 3444 3.2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. 6. Enable the SIR system. Page 5795 Splice Pack SP203 Part 1 Page 6079 Abbreviations And Meanings - Part 2 Page 7534 Disclaimer Page 4025 Valve Body Spring and Bore Plug Chart (inch) Page 2147 Powertrain Control Module (PCM) Connector C1 Part 3 Page 5401 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 7694 Abbreviations And Meanings - Part 22 Page 5670 C204 (Column Shifter Plug To Body Harness) Page 7233 Page 9514 Abbreviations And Meanings - Part 10 Page 7649 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 3139 Steps 13-14 Service and Repair Sun Shade: Service and Repair SUNROOF SUNSHADE PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof glass. 2. Slide the sunshade forward. 3. Flex the center of the sunshade downward while pulling up and forward on the front center of the sunshade. 4. Pull the sunshade forward until the front tabs release from the track slots. 5. Flex the center of the sunshade downward and release the rear tabs from the track slots. INSTALLATION PROCEDURE 1. Insert the rear tabs of the sunshade into the track slots. 2. Carefully slide the sunshade rearward until the front tabs are aligned with the track slots. 3. Push the front tabs through the track slots. 4. Slide the sunshade rearward. 5. Install the sunroof glass. Page 1083 Brake Fluid: Description and Operation Brake Fluid and Brake Fluid Handling Use extreme care when selecting brake system fluids or seal damage can result. Do not reuse brake system fluids. Do not mix power steering fluid with brake fluid. Fluid contamination may result in swelling and deterioration of rubber parts. This can lead to reduced brake performance and the eventual loss of braking capability. Service booster components in a clean work area separate from the brake servicing area. Wash hands before changing work areas. Do not use the same containers for brake and power steering fluids. Caution: Brake fluid may be irritating to the skin or the eyes, or may cause nausea, vomiting, or diarrhea if swallowed. In case of contact or swallowing take the following actions: ^ Eye contact - rinse thoroughly with water ^ Skin contact - wash with soap and water ^ if swallowed - Contact a physician immediately. Give two glasses of water and induce vomiting by sticking fingers down the throat. Notice: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills. Always store brake fluid in a closed, sealed container. Never use previously opened containers of stored brake fluid. Always use new brake fluid from a sealed container. Brake fluid left in open or improperly sealed containers will absorb moisture. Moisture can lower the brake fluid boiling point, causing the following problems: ^ Brake system contamination ^ Corrosion ^ Deterioration of rubber components Substandard Or Contaminated Brake Fluid It the brake fluid contains improper fluid, water, or other contaminates, the brake fluid may boil or may deteriorate rubber components in the hydraulic brake system. Evidence of rubber deterioration occurs in the following areas: ^ Swollen master cylinder piston seals ^ Swelling of the wheel cylinder boots ^ Swelling of caliper boots ^ Swelling of the master cylinder reservoir diaphragm If rubber deterioration is found, replace all rubber parts, including the hoses, in the brake system. Inspect for brake fluid on the brake linings. Replace the brake linings that are contaminated with brake fluid. If the brake fluid is contaminated and the master cylinder piston seals are good, check for leaks and excessive heat conditions. If no leaks or excessive heat conditions are found, flush the brake system. Flushing The Hydraulic Brake System In order to flush the brake hydraulic system, run new brake fluid through the brake system. Continue until the brake fluid at each bleeder valve comes out clear. Flushing is the only way to clean contaminated fluid out of the system. Flush the brake hydraulic system for the following reasons: ^ New hydraulic brake parts are installed ^ Contamination may be present ^ You do not know the grade of brake fluid in the brake system ^ Mineral oil is present in the brake fluid Page 313 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting bolt. Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). Page 5128 Abbreviations And Meanings - Part 21 Page 3811 Disclaimer Page 7264 Arrows And Symbols Uses various symbols in order to describe different service operations Page 2702 Abbreviations And Meanings - Part 22 Service and Repair Radiator Cooling Fan Motor: Service and Repair Fan Replacement ^ Tools Required J 46406 Fan Clutch Wrench Removal Procedure 1. Remove the upper fan shroud. 2. Remove the fan clutch assembly in a counterclockwise direction using the J 46406. 3. Remove the fan clutch assembly from the vehicle. 4. Remove the fan blade mounting bolts. 5. Remove the fan blade from the fan clutch. Installation Procedure Page 7836 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Inner Removal Procedure 1. Remove the side front door trim panel. 2. Remove the staples that secure the sealing strip to the trim panel. 3. Remove the sealing strip. Installation Procedure 1. Position the sealing strip on the trim panel. 2. Install the sealing strip to the trim panel using the original staples or a heavy-duty staple gun. 3. Install the side front door trim panel. Page 130 Blower Motor Relay Specifications Coolant Reservoir: Specifications Coolant Recovery Reservoir Nuts .................................................................................................................................................... 8 11 Nm (6 - 8 ft. lbs.) Page 7556 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7134 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 7648 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 8770 Liftglass/Endgate Lock Cylinder Switch Page 1409 The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears Specifications Engine Oil Pressure: Specifications Lubrication System Oil Pressure - at 1,000 RPM ................................................................................................................ ........................................................ 42 kPa (6 psi) Oil Pressure - at 2,000 RPM ............................... ..................................................................................................................................... 125 kPa (18 psi) Oil Pressure - at 4 000 RPM ......................................................................................................... ........................................................... 166 kPa (24 psi) Page 5722 C116 C2 (Engine Harness To Active Transfer Case Harness) Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 8539 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Disconnect the memory seat module harness connectors. 3. Remove the 2 screws securing the memory module bracket to the seat adjuster frame. 4. Remove the memory module bracket with the module. 5. Remove the module from the bracket. INSTALLATION PROCEDURE Page 2707 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 982 Drive Belt Squeal Diagnosis Step 1 - 9 Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Page 2503 Body Control Module (BCM) C3 Part 2 Page 7307 Garage Door Opener Page 2305 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 5665 C203 (Body Harness To IP Harness) Part 6 Page 8123 3. Open the console lid. 4. Remove the console compartment inserts. 5. Remove the transmission select switch (if equipped). 6. Remove the nuts that retain the rear of the console. 7. Remove the cup holder insert. 8. Remove the screws that retain the front of the console to the vehicle. 9. Remove the console from the vehicle. Installation Procedure 1. Install the console to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the front of the console. Tighten the screws to 7 N.m (63 lb in). 3. Install the cup holder insert. 4. Install the nuts that retain the rear of the console. Tighten the nuts to 10 N.m (89 lb in). Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6123 Tie Rod: Service and Repair Tie Rod Replacement ^ Tools Required J 6627-A Tie Rod Puller - J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the cotter pin from outer tie rod ball stud nut. 3. Remove the outer tie rod ball stud nut. 4. Remove the inner tie rod ball stud nut. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. Important: Use the proper tool in order to separate all tie rods and ball joints. Page 3806 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 8996 Abbreviations And Meanings - Part 8 Page 9058 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Testing and Inspection Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids Inspect the connectors at the BCM, and all other circuit connecting points for an intermittent condition. Inspect the circuit wiring for an intermittent condition. If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Page 5272 Multiple Junction Connector: Diagrams C300 - C317 C300 (Dome Lamp Harness To Sunroof Harness) Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement ^ Tools Required J 42371 Clutch Line Release Tool Removal Procedure 1. Remove the master cylinder rod from the clutch pedal. 2. Turn the master cylinder 45 degrees clockwise to unlock the master cylinder. 3. Disconnect the wiring harness from the clutch master cylinder start switch. 4. Remove the clips securing the clutch line to the dash panel and heat shield. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 4904 Abbreviations And Meanings - Part 4 Page 5188 Fuse Block - Underhood Connector C4 Part 4 Page 33 Disclaimer Page 3400 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 2296 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 7637 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Procedures Heated Glass Element: Procedures Bus Bar/Antenna Terminal Repair BUS BAR/ANTENNA TERMINAL REPAIR 1. Clean the repair area by buffing with fine steel wool. This removes the oxide coating formed during the window manufacture. IMPORTANT: The rear defogger bus bar lead wire, the antenna, or the defogger terminal can be reattached by resoldering using a solder containing 3 percent silver and a rosin flux paste. 2. Install the paste-type rosin flux in small quantities to the rear defogger bus bar lead wire antenna or the defogger terminal repair area using a brush. 3. Coat the solder iron tip with the solder. - Use only enough heat to melt the solder. - Use only enough solder to ensure a complete repair. NOTE: Use only enough heat to melt the solder. Using excessive heat can damage the rear window defogger components or the rear window. 4. Install the solder to the feed bus bar or the ground bus bar. 5. Draw the soldering iron tip across the fluxed area, thinly coating the bus bar with solder. 6. Install a small amount of flux to the underside of the rear defogger bus bar lead wire antenna or the defogger terminal. 7. Align the spots with flux to the underside of the rear defogger bus bar lead wire, antenna, or defogger terminal. 8. Coat the tip of the soldering iron with solder. 9. Install the solder to the underside of the rear defogger bus bar lead wire antenna to the defogger terminal. 10. Draw the iron across the fluxed spot, thinly coating the spot of solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. - Use pliers in order to hold the rear defogger bus bar lead wire antenna or the defogger terminal. - Apply the heat to the top of the rear defogger bus bar lead wire antenna or the defogger terminal. This causes the solder spot to melt and fuse together. - Do not remove the holding force until the solder has solidified. - Wipe off the excess flux with solvent. 12. Install the electrical connector. Grid Line Repair GRID LINE REPAIR TOOLS REQUIRED - J 25070 Heat Gun - Capable of 260°C (500°F) or equivalent - Test Lamp - Rear Window Defogger Repair Kit GM P/N 12346001, Canada P/N 10951643 or equivalent REMOVAL PROCEDURE 1. Disconnect the electrical connector. CAUTION: To avoid personal injury: Do not allow the repair material to come in contact with skin or eyes and avoid breathing vapors. - Do not use near sparks or open flame. 1. Inspect the rear window grid lines. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 7229 Page 9772 Page 5978 1. Install the power steering gear return hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering gear return hose to the power steering gear. Tighten the power steering gear return hose to the power steering gear to 30 Nm (22 ft. lbs.). 3. Connect the wiring harness clip to the power steering return hose at the power steering gear. 4. Connect the power steering gear return hose to the power steering cooler, if equipped. Tighten the power steering gear return hose to the power steering cooler clamp to 2 Nm (18 inch lbs.). 5. Connect the power steering gear return hose to the power steering pump (for vehicles without a power steering cooler). Tighten the power steering hose clamp to 2 Nm (18 inch lbs.). 6. Remove the drain pan from under the vehicle. 7. Install the air cleaner assembly. 8. Bleed the power steering system. Page 3277 Page 5604 Fuse Block - Underhood Connector C6 Relay Block - Body Page 9542 Steps 1-4 Page 4680 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the two electrical harness connectors from the EBCM (2). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 2. Disconnect the 5 brake lines from the BPMV (3). 3. Remove 2 bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 4. Disconnect the 2 way ABS pump motor connector. 5. Remove the four T-25 TORX screws (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 7. Clean the EBCM (2) to BPMV (3) mounting surfaces with a clean cloth. Installation Procedure Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) onto BPMV (3). Page 9417 Registered And Non-Registered Trademarks - Part 3 Page 2679 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 8958 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 9733 Abbreviations And Meanings - Part 23 Page 7488 Speaker - RR (2-Door Utility) Page 1446 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: ^ The wheel/nut has the word Metric stamped on the face. ^ The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters gap per thread Page 5766 C402 (Body Harness To RH Tail Lamp Harness) (Domestic) Page 2384 Engine Harness Rear (4.3L) Page 1799 Balance Shaft: Technical Service Bulletins Engine - Balance Shaft Rattling Noises (Cancellation) Bulletin No.: 00-06-01-023C Date: August 30, 2006 TECHNICAL Subject: Engine/Balance Shaft "Rattle" Noise Models: 1992-2003 Chevrolet and GMC C/K, S/T, M/L, G and P Models 1992-2001 Oldsmobile Bravada with 4.3 L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to cancel this bulletin. Please discard Corporate Bulletin Number 00-06-01-023B (Section 06 -- Engine/Propulsion System). Technicians should refer to Corporate Bulletin Number 03-06-01-024C for information on engine/balance shaft "rattle" noise concerns. Disclaimer Page 8359 WA9792/39 - WA990A/19U Page 5568 Fuse: Application and ID Underhood Fuse Block Fuse Block - Underhood Details (Uplevel Utility) Application Table Part 1 Page 5441 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 4560 3. Remove the brake caliper mount. 4. Remove and dispose of the sheet metal rotor retainers. 5. Remove the brake rotor. 6. Inspect the brake rotor. 7. Refinish the brake rotor if necessary. Installation Procedure Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. Notice: Whenever the rotor has been separated from the axle flange, clean any rust or foreign material from the mating surface of the axle flange and brake rotor. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Using the J42450-A, clean the axle flange. Page 5081 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 7050 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 5322 C203 (Body Harness To IP Harness) Part 10 Page 3650 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 632 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Engine Controls - Excessive Fuel Gauge Fluctuation PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Excessive Fuel Gauge Fluctuation Bulletin No.: 03-08-49-014A Date: October 02, 2003 TECHNICAL Subject: Fuel Gauge Fluctuates Between E and 1/4 Tank, Goes From 1/4 to Empty Too Quickly, Excessive Empty Fuel Reserve (Reprogram PCM) Models: 2001-2003 Chevrolet Blazer 2001 GMC Envoy 2001-2003 GMC Jimmy Supercede: This bulletin is being revised to add condition information. Please discard Corporate Bulletin Number 03-08-49-014 (Section 08 - Body and Accessories). This bulletin contains three different conditions depending on the model year of the vehicle involved. Condition # 1 (2001 4-Door Only) Some customers may comment that the fuel gauge goes from 1/4 to empty too quickly. Condition # 2 (2002 4-Door Only) Some customers may comment about excessive empty fuel reserve. Condition # 3 (2003 2-Door and 4-Door) Some customers may comment that the fuel gauge fluctuates between E and 1/4 tank. Correction Important: In order to select the correct calibration on some vehicles, you must first identify the cluster part number. This can be done using the Tech 2. DO NOT REMOVE THE CLUSTER. A new service calibration has been released to correct these conditions. Reprogram the PCM using the new service calibration, which was available from Techline starting August 25, 2003 on the TIS2000 version 9.0 or later. This calibration is an electronic calibration and is not available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Locations Door Wiring Harness (RR Shown, LR Similar) Page 2039 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 5514 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 966 Disclaimer Page 9579 Page 776 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 9009 Abbreviations And Meanings - Part 21 Diagrams Power Seat Control Module: Diagrams Memory Seat Module - Driver C1 Part 1 Page 9615 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 4359 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Page 5337 C224 (Body Harness To Ashtray Insert) Page 8614 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 1755 7. Install the lower intake manifold onto the engine block. 8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953433) or equivalent to the threads of the lower intake manifold bolts. 9. Install the lower intake manifold bolts. Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. Refer to Fastener Notice in Service Precautions. 10. Tighten the lower intake manifold bolts. 10.1. Tighten the bolts on the first pass in sequence to 3 Nm (27 inch lbs.). 10.2. Tighten the bolts on the second pass in sequence to 12 Nm (106 inch lbs.). 10.3. Tighten the bolts on the final pass in sequence to 15 Nm (11 ft. lbs.). 11. Position the power steering pump mounting bracket. Page 3609 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 8709 Registered And Non-Registered Trademarks - Part 2 Page 1120 1. Apply sealant to the oil drain plug threads. Use Teflon (R) GM P/N 1052080, or the equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Use the J 36511 in order to install the oil drain plug. ^ Tighten the oil drain plug to 30 Nm (22 ft. lbs.). 3. Fill the transmission to the level of the fill plug hole. Page 5700 C402 (Body Harness To RH Tail Lamp Harness) (Export) Page 2543 Disclaimer Page 4979 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 3. Remove the two screws from the rotor. 4. Remove the rotor. Page 8624 Seat Cushion: Removal and Replacement Seat Cushion Trim Cover and Pad Replacement (Bench) Seat Cushion Trim Cover and Pad Replacement (Bench) Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the seat back release lever, if equipped. 3. Remove the seat back. 4. Separate the J-strips from the seat bottom frame. 5. Remove the manual lumbar knob lever, if equipped. 6. Remove the seat bottom cover. 7. Remove the seat bottom pad. Installation Procedure 1. Install the seat bottom pad to the seat bottom. 2. Install the seat bottom cover over the pad. 3. Engage the J-strips to the seat bottom frame. 4. Install the seat back. 5. Install the seat back release lever, if equipped. 6. Install the manual lumbar knob lever, if equipped. 7. Install the seat to the vehicle. Seat Cushion Trim Cover and Pad Replacement (Bucket) Seat Cushion Trim Cover and Pad Replacement (Bucket) Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the cupholder and bracket, if equipped. 3. Remove the seat back recliner assembly, if equipped. Page 3367 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Page 1603 15. Remove the J 22794. 16. Install the spark plugs. 17. Install the valve rocker arms to the cylinder head. 18. Install the valve rocker arm cover. Page 1198 Application Table Part 5 Service and Repair Grille: Service and Repair Grille Replacement (Chevrolet) Removal Procedure 1. Open the hood. 2. Remove the grille by pulling it forward out of the radiator support. 3. Disconnect the headlamp washer filler hose from the grille. 4. Remove the park/turn signal bulb assembly from the lens. 5. Remove the fog lamp bulb assembly from the lens, if equipped. 6. If replacing the grille, remove the park turn signal lamp/fog lamp assembly from the grille. Refer to Front Fog Lamp - Park/Turn Signal Assembly Replacement in Lighting Systems Installation Procedure 1. If removed, install the park turn signal/fog lamp assembly to the grille. Refer to Front Fog Lamp Park/Turn Signal Assembly Replacement in Lighting Systems. 2. Install the fog lamp bulb assembly to the lens, if removed. 3. Install the park/turn signal bulb assembly to the lens. 4. Connect the headlamp washer filler hose to the grille. 5. Install the grille by pressing into place until fully seated. 6. Close the hood. Page 5179 Fuse Block - Underhood Connector C2 Part 2 Locations Clutch Switch: Locations Instrument Panel, LF Page 5755 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 2 Page 9147 Abbreviations And Meanings - Part 25 Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 853 Frame Angle Measurement (Express / Savana Only) ........ Page 2797 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The Powertrain Control Module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The Ignition Control (IC) - The Knock Sensor (KS) system - The Evaporative Emissions (EVAP) system - The Secondary Air Injection (AIR) system (if equipped) - The Exhaust Gas Recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the Malfunction Indicator Lamp (MIL). When the PCM detects a malfunction, the PCM stores a Diagnostic Trouble Code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. Page 4501 2. Install the brake caliper bolts to the mounting bracket. Tighten the brake caliper bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Installing Hoses without Twists or Bends Notice in Service Precautions. Important: When performing the following service procedure, DO NOT reuse the old bolt washers. Always use new washers. 3. Install the brake hose bolt and washers. Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 4. Fill the brake master cylinder to the proper level. 5. Bleed the brake calipers. 6. Install the tire and wheel assembly, 7. Lower the vehicle. Refer to Vehicle Lifting. Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Step 1 - 15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the Diagrams Tow/Haul Switch Page 97 Power Seat Control Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Disconnect the memory seat module harness connectors. 3. Remove the 2 screws securing the memory module bracket to the seat adjuster frame. 4. Remove the memory module bracket with the module. 5. Remove the module from the bracket. INSTALLATION PROCEDURE Page 2323 Engine Harness Rear (4.3L) Page 9129 Abbreviations And Meanings - Part 7 Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 8763 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. INSTALLATION PROCEDURE Page 7817 5. Install the front door lower striker bolt. 6. Install the rear lower striker bolt. Notice: Refer to Fastener Notice in Service Precautions. 7. Adjust the door striker in order to properly engage the door latch, if necessary. Loosen the door striker bolts in order to adjust the door striker. Tighten the door striker bolts to 22 N.m (16 lb ft). Page 7952 Guide the cable through the cowl panel underneath the instrument panel from the inside of the vehicle. Installation Procedure 1. Install the hood latch assembly to the vehicle. Guide the cable through the cowl panel underneath the instrument panel from the inside of the vehicle. 2. Guide the cable along the left fender behind the antilock brake module, the underhood fuse block, and the windshield wiper/washer reservoir. 3. Route the cable around the end of the radiator support. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the hood release cable and the lever bolts to the cowl side panel. Tighten the hood release cable and the lever bolts to 9 N.m (80 lb in). 5. Secure the release cable to the side of the cowl with adhesive tape. 6. Install the hood release cable to the retaining clips. Page 6078 Abbreviations And Meanings - Part 1 Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Page 3279 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Locations Electronic Components Page 3618 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 9485 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing ^ Tools Required J 24460-01 Cooling System Pressure Tester Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 9369 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 496 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Page 4203 Fluid - M/T: Service and Repair NV 3500 Fluid Replacement ^ Tools Required J36511 Oil Fill/Drain Plug Hex Bit Removal Procedure 1. Raise and support the vehicle. 2. Using J 36511 remove the oil fill and drain plugs. Drain the oil in a suitable container. Installation Procedure 1. Apply sealant to the oil drain plug threads. Use sealant GM P/N 12346004 or the equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 36511 install the oil drain plug. ^ Tighten the oil drain plug to 30 Nm (22 ft. lbs.). Page 5482 Page 4388 2. Install the following parts: 2.1. The O-ring on the vehicle speed sensor assembly. 2.2. The vehicle speed sensor assembly. 2.3. Tighten Tighten the bolt to 16 Nm (12 ft. lbs.). 3. Install the electrical connector to the vehicle speed sensor. 4. Lower the vehicle. Powertrain Control Module (PCM) Connector C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C1 Powertrain Control Module (PCM) Connector C1 Part 1 Page 2978 Engine Harness Rear (4.3L) Page 6873 7. Remove the bolt that retains the seat belt retractor assembly to the vehicle. 8. Remove the seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt retractor assembly to the vehicle. 2. Install the bolt that retains the rear seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt retractor assembly bolt to 70 N.m (52 lb ft). 3. Guide the seat belt through the opening in the body side trim panel. 4. Install the body side trim panel. Locations Electronic Components Page 3108 9.4. Inspect for fuel leaks. Page 5002 Conversion English/Metric Part 1 Page 1884 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots » turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Page 5647 C104 (Chassis Harness To Engine Harness) A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 5942 Pitman Arm: Specifications Pitman Arm to Steering Gear Nut 185 ft. lbs. Pitman Arm to Relay Rod Nut (RWD) 36 ft. lbs. Page 1212 Fuse Block - Underhood Connector C1 Part 3 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6035 Page 695 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Page 7672 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 6468 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Luggage Carrier Replacement Luggage Rack: Service and Repair Luggage Carrier Replacement Luggage Carrier Replacement Removal Procedure 1. Remove the screws from the luggage carrier end supports. 2. With an assistant, remove the luggage carrier from the roof as an assembly. 3. Remove the screws from the side rail supports. 4. Remove the side rail supports from the side rails. 5. Remove the screws from the cross rails. 6. Remove the cross rails from the sliders. 7. Remove the rubber strips from the cross bar assemblies. 8. Remove the tap plates from the cross rails. 9. Loosen the knobs from the sliders and the lock plates in the slide rails. Installation Procedure 1. Install the sliders and the lock plates into the slots on the side rails. 2. Hand-tighten the knobs into the sliders and the lock plates. Page 3401 Engine Generator And Starter Page 1334 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Locations Electronic Components Page 2959 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 7624 Page 5719 C108 - Electric Shift Transfer Case Extension Harness To Body Harness, NP1 Page 9773 Page 6472 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 1581 9. Remove the valve rocker arm cover bolts. 10. Remove the valve rocker arm cover bolt grommets. 11. Discard the valve rocker arm cover bolt grommets. 12. Remove the valve rocker arm cover. 13. Remove the valve rocker arm cover gasket. 14. Discard the valve rocker arm cover gasket. 15. Clean the valve rocker arm cover in cleaning solvent. 16. Dry the valve rocker arm cover with compressed air. Page 4215 1. Raise and support the vehicle 2. Remove the rear propeller shaft. 3. Remove the rear oil seal from the rear case using the J 6125-1B (1) and the J 23129 (2). Installation Procedure 1. Using the J 36503 install the new rear oil seal. 2. Install the rear propeller shaft. 3. Check the transmission oil level. 4. Lower the vehicle. Locations Steering Column Components Page 7944 1. Install the bolts that retain the primary hood latch to the mounting bracket. Tighten the primary hood latch mounting bolts to 25 N.m (18 lb ft). 2. Position the primary hood latch assembly on the radiator support. 3. Use the marks in order to align the bracket. 4. Install the bolts that retain the primary hood latch to the mounting bracket. Tighten the primary hood latch mounting bracket bolts to 25 N.m (18 lb ft). 5. Install the cable to the primary hood latch assembly, by performing the following procedures: 1. Install the cable housing into the primary latch. 2. Install the cable into the latch container clip. 6. Inspect the operation of the hood latch. 7. Close the hood. Page 8375 WA605H/45 - WA711J/58 Page 785 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Procedures Ash Tray: Procedures ASHTRAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel trimplate. 2. Remove ashtray housing retaining screws. 3. Move the ashtray housing rearward in order to disconnect the electrical connectors. 4. Remove the clip that retains the electrical connectors to the instrument panel. 5. Disconnect the electrical connectors. 6. Remove the ashtray housing from the instrument panel. INSTALLATION PROCEDURE 1. Install the ashtray housing to the instrument panel. 2. Position the ashtray housing in order to connect the electrical connectors. 3. Connect the electrical connectors. 4. Install the electrical connector retaining clip to the instrument panel. 5. Install the screws that retain the ash tray housing to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). 6. Install the instrument panel trimplate. Page 3773 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 9080 Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 7794 2. Remove the handle retaining bolt. 3. Release the handle locator tab from the locator cutout, by sliding the handle forward. 4. Release the rod retainer locks. 5. Remove the rods from the handle. 6. Remove the handle from the door. Installation Procedure 1. Position the handle to the door. 2. Install the rods to the handle. 3. Install the rod retainer locks. 4. Insert the handle locator tab into the locator cutout and move the handle rearward, indexing the fastener hole to the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the handle retaining bolt. Tighten bolt to 10 N.m (88 lb in). 6. Install the door trim panel. Page 8394 WA900J/59 - WA9260/74 Page 8634 Locations Seat Switches Page 5782 C501 (Body Harness To LH Front Door Harness) (4-Door) Part 1 Page 1708 Oil Line: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 3178 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 6174 1. Install the stabilizer shaft. 2. Install the stabilizer shaft link lower mounting bolt. 3. Install the stabilizer shaft link upper mounting bolt. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer shaft link mounting nuts. ^ Tighten the stabilizer shaft link lower mounting nut to 57 Nm (42 ft. lbs.). ^ Tighten the stabilizer shaft link upper mounting nut to 35 Nm (25 ft. lbs.). 5. Lower the vehicle. (2-Door Utility) Stabilizer Shaft Link Replacement (2-Door Utility) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Page 3598 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side Page 7313 Steps 1-9 A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 9046 16. Install the new compass mounting bracket. 17. Install the compass mounting bracket screw. Tighten Tighten the screw to 1.9 N.m (17 lb in). 18. Connect the console electrical connectors. 19. Insert the console mounting tabs into the mounting bracket and push upward on the rear of the console in order to install the console. 20. Install the screw at the front of the console. Tighten Tighten the screw to 1.9 N.m (17 lb in). 21. Calibrate the compass. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8115 1. Install the console to the vehicle. 2. Install the screws that retain the front of the console. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 7 N.m (63 lb in). 3. Install the cup holder insert. 4. Install the nuts that retain the rear of the console. Tighten Tighten the nuts to 10 N.m (89 lb in). 5. Install the transmission select switch (if equipped). Page 7236 Page 8993 Abbreviations And Meanings - Part 5 Page 1954 5. Remove the coolant recovery reservoir. 6. Drain the coolant from the reservoir. Installation Procedure 1. Install the coolant recovery reservoir. Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the reservoir retaining nuts. Tighten the nuts to 8 - 11 Nm (6 - 8 ft. lbs.). Page 6138 13. Remove the rivets from the upper ball joint. 14. Use a 3.175 mm (1/8 inch) drill in order to cut a 6.35 mm (1/4 inch) deep hole in the center of each rivet. 15. Drill away the rivet heads. Use a 12.7 mm (1/2 inch) drill. 16. Punch the rivets out. Use a small pin punch. Service and Repair Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Removal Procedure 1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park brake cable. 4. Remove the park brake release handle. 5. Press the retaining tabs in on the front park brake cable. 6. Remove the front park brake cable from the park brake pedal. 7. Remove the park brake pedal mounting bolts. 8. Remove the park brake pedal assembly. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 9077 Page 7635 Page 3774 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 6412 3. Remove the rotor. 4. Remove the wheel stud from the axle flange using the J 43631. Installation Procedure 1. Install the stud into the axle flange. 2. Install the 4 washers and the lug nut to the stud 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the rotor. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Page 3356 Ignition Control Module (ICM) Page 3475 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 7257 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 783 Conversion English/Metric Part 2 Page 2034 4. Install the coolant recovery reservoir hose to the lower fan shroud. 5. If equipped with the 2.2L, install the air intake duct assembly: Tighten the intake air duct clamps 5 Nm (44 inch lbs.). 6. Install the push pins (2). Page 7503 Use a scrubbing action, non-abrasive cleaning cassette (part of J 39916-A ) for proper tape player cleaning. This cleaner is a wet-type cleaning system. The wet-type cleaning system uses a cleaning cassette with pads. The pads scrub the tape head as the hubs of the cleaner cassette turn. If you use this type of cleaner, the following conditions may occur: - The radio displays an error. - The cartridge ejects. These conditions are normal and is the result of an added feature in the tape player that detects broken tapes. If an error occurs, insert the cleaning cassette at least 3 times in order to thoroughly clean the tape player. You can also use a non-scrubbing action, wet-type cleaner. This type of cleaner uses a cassette with a fabric belt which cleans the tape head. This type of cleaning cassette will not cause an error, but may not clean the tape player as thoroughly as the scrubbing type cleaner. Page 1057 Hose/Line HVAC: Service and Repair Suction Screen Installation SUCTION SCREEN INSTALLATION TOOL REQUIRED J 44551 Suction Screen Kit IMPORTANT:Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert J 44551 -6 sizing tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel (1) to J 44551 -5. Door Window Weatherstrip Sunroof / Moonroof Wiring Harness: Service and Repair Sunroof Wiring Harness Replacement RPO Code Zrx/Extreme W/CF5 SUNROOF WIRING HARNESS REPLACEMENT WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. Remove the 15A fuse from the sunroof fused jumper wire at the lower fuse block. 2. Remove the sunroof panel window garnish molding (3). 3. Disconnect the sunroof power feed connector (1) at the front header. 4. Remove the LF windshield pillar garnish molding. 5. Remove the LF sunshade and retainer. Page 5255 C203 (Body Harness To IP Harness) Part 10 Page 5821 Location View Page 8460 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement With RPO Code Zrx/Extreme W/CF5 SUNROOF SWITCH REPLACEMENT (ZRX/EXTREME W/CF5) REMOVAL PROCEDURE 1. With a medium flat-bladed tool, remove the motor/actuator service cover. 2. Remover the motor/actuator trim cover screw (2). 3. Lower the trim cover (5). 4. Remove the switch (4) from the cover. 5. Disconnect the motor/actuator electrical connector (3). 6. Remove the ground screw (3) and ground wire (2) from the header in behind the motor/actuator. Page 8765 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. Installation Procedure 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. Page 4639 14. Remove the brake caliper mounting bolt sleeves. 15. Remove the rubber O-rings. 16. Discard the rubber O-rings. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent. 2. Dry the brake caliper pin bolts using non-lubricated, compressed filter air. 3. Lubricate the sleeves and bushings with Delco Silicone Lube, GM P/N 18010909, or equivalent. 4. Install the rubber O-ring bushings to the brake caliper. 5. Install the brake caliper mounting bolt sleeves. 6. Install the brake pads to the brake caliper. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the brake caliper mounting bolts. Tighten the brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Brake Hose Installation Notice in Service Precautions. Page 1599 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 5892-D Valve Spring Compressor - J 42073 Valve Stem Seal Installer Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the required valve rocker arms. 3. Remove the required spark plugs. 4. Install the J 22794 into the spark plug hole. 5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 6. Remove a bolt from a valve rocker arm. 7. Install a flat washer on the bolt. 8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 9. Use the J 5892-D in order to compress the valve spring. 9.1. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Page 6288 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 4268 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 4529 14. Remove the anti/raffles springs from the mounting bracket. 15. Inspect the brake caliper. Installation Procedure Important: When replacing the rear brake pads, DO NOT reuse the old anti/rattle springs use supplied in the brake pad kit. 1. Install the NEW anti/rattle springs on the mounting bracket. 2. Install the rear brake pads on the mounting bracket. Page 4494 1. Lubricate the following parts with clean brake fluid. ^ The piston ^ The piston seal ^ The brake caliper bore. Important: Ensure that the piston seal is not twisted in the brake caliper bore groove. 2. Install the piston seal. 3. Install the boot on the piston. 4. Install the piston in the caliper bore. Page 9525 Abbreviations And Meanings - Part 21 Page 9010 Abbreviations And Meanings - Part 22 Page 1865 Disclaimer Page 3740 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 2233 Engine Generator And Starter Page 7732 Body Control Module (BCM) C2 Part 3 Page 2668 Equivalent - Decimal And Metric Part 2 Page 5698 C317 (Body Harness To Driver's Seat Assembly Pigtail Connector) Page 7685 Abbreviations And Meanings - Part 13 Page 6525 Abbreviations And Meanings - Part 26 Page 206 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 8325 WA253A/86 - WA379E/86 Page 616 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Specifications Engine Oil Pressure: Specifications Lubrication System Oil Pressure - at 1,000 RPM ................................................................................................................ ........................................................ 42 kPa (6 psi) Oil Pressure - at 2,000 RPM ............................... ..................................................................................................................................... 125 kPa (18 psi) Oil Pressure - at 4 000 RPM ......................................................................................................... ........................................................... 166 kPa (24 psi) Page 4882 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Control Module C1 Page 9636 Abbreviations And Meanings - Part 17 Diagrams Power Mirror Switch: Diagrams Outside Rearview Folding Mirror Switch (Export) Page 9734 Abbreviations And Meanings - Part 24 Page 172 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 1226 Fuse Block - Underhood Connector C4 Part 2 Page 3922 11. Ensure that the steering column shift lever is in the NEUTRAL position. 12. Raise the vehicle. 13. Install the range selector cable to the bracket. 14. Install the retainer (1) to the range selector cable and transmission bracket. 15. Ensure that the transmission range selector lever is in the NEUTRAL position. 16. Following the adjustment procedure, install the range selector cable (2) to the range selector cable lever ball stud (1). Refer to Automatic Transmission Range Selector Cable Adjustment. 17. Install the positive assurance pin to the bracket. 18. Install the transfer case shield, if equipped. Refer to the appropriate procedure: ^ Transfer Case Shield Replacement in Transfer Case-NVG 233-NP1 ^ Transfer Case Shield Replacement in Transfer Case-NVG 236-NP8 19. Lower the vehicle and check for proper operation. Repeat the adjustment procedure if necessary. Refer to Automatic Transmission Range Selector Cable Adjustment. Page 5073 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 5572 Application Table Part 5 Locations SIR Components Front Suspension Stabilizer Link: Service and Repair Front Suspension Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the to the stabilizer shaft link retaining nut. 4. Remove the retainers from the stabilizer shaft link bolt. 5. Remove the grommets from the stabilizer shaft link bolt. 6. Remove the following parts from the stabilizer shaft link bolt: 6.1. The grommet 6.2. The retainer 6.3. The spacer 6.4. The retainer 6.5. The grommet Installation Procedure 1. Install the retainers and the grommets to the stabilizer shaft link bolt. Position the parts correctly. 2. Install the stabilizer shaft link bolt through the lower control arm hole. Stack the parts in the following order: 2.1. The grommet 2.2. The retainer 2.3. The spacer 2.4. The retainer 2.5. The grommet 3. Install the stabilizer shaft link bolt through the upper control arm hole. 4. Install the grommets to the stabilizer shaft link bolt. 5. Install the retainers to the stabilizer shaft link bolt. Page 3756 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 1243 Application Table Part 2 Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Fuse Block - Underhood Location View Page 9486 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 351 5. Locate the clip directly centered over the white paint mark on the wheel speed sensor cable. 6. Install harness clips and 13 mm fastening bolt and nut to the front side of the upper control arm 7. Install the hub and rotor. 8. Install brake caliper. 9. Install tire and wheel. 10. Lower the vehicle. Refer to Vehicle Lifting. Specifications Compression Check: Specifications Compression Pressure Limit ............................................................................................................... ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest. Page 7822 1. Install the striker and shim(s) to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the striker to the roof panel. 3. Adjust the striker using the procedure below: * Tighten the bolts to a sung fit. * Close the door to self align striker. * Check for door fit. * Add or remove shims as required (maximum of 3). Tighten the striker bolts to 10 N.m (89 lb in). IP Fuse Block Details Fuse: Application and ID IP Fuse Block Details Location View Application Table Part 1 NV 1500 Fluid - M/T: Service and Repair NV 1500 Transmission Fluid Replacement ^ Tools Required J36511 Oil Fill/Drain Plug Hex Bit (17 mm) Removal Procedure 1. Raise the vehicle. 2. Thoroughly clean around the fill plug and the oil drain plug. 3. Use the J 36511 in order to remove the oil fill plug. 4. Catch the oil in a suitable container. 5. Use the J 36511 in order to remove the oil drain plug. Installation Procedure Page 5523 Abbreviations And Meanings - Part 2 Page 6483 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 8356 WA9260/74 - WA9539/47 Page 801 Abbreviations And Meanings - Part 10 Page 6521 Abbreviations And Meanings - Part 22 A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 5826 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 2722 Step 11 Page 799 Abbreviations And Meanings - Part 8 Page 6444 Air Register: Service and Repair Rear Floor AIR OUTLET REPLACEMENT - REAR FLOOR (UTILITY ONLY) REMOVAL PROCEDURE 1. Remove the passenger front seat and the driver front seat. 2. Remove the center floor console. 3. Remove the passenger and driver door sill plates. 4. Remove the passenger and driver side kick panels. 5. Pull the carpet back in order to access the rear floor air outlets. 6. Remove the passenger seat wiring harness from the right rear floor air outlet. 7. Remove the rear floor air outlets from the center floor air outlet. 8. Remove the rear floor air outlets from the vehicle. INSTALLATION PROCEDURE 1. Install the rear floor air outlets to the center floor air outlet. 2. Install the passenger seat wiring harness to the right rear floor air outlet. 3. Install the carpet. 4. Install the passenger and driver side kick panels. 5. Install the passenger and driver door sill plates. 6. Install the center floor console. 7. Install the passenger front seat and the driver front seat. Page 9839 Abbreviations And Meanings - Part 25 Page 8048 Rear Fender Liner: Removal and Replacement Wheelhouse Extension Replacement Wheelhouse Extension Replacement Removal Procedure 1. Remove the wheelhouse extension retainers. 2. Remove the wheelhouse extension. Installation Procedure 1. Install the wheelhouse extension. 2. Install the wheelhouse extension retainers. Sight Shield Replacement - Rear Wheelhouse Panel Sight Shield Replacement - Rear Wheelhouse Panel Removal Procedure 1. Remove the push-pins retaining the sight shield to the vehicle frame. 2. Remove the sight shield. Installation Procedure Page 7237 Page 9854 Power Window Switch: Service and Repair POWER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power window switch from the trim panel by using a flat-bladed tool in order to pry upward on the leading edge. 2. Disconnect the electrical connector from the switch. Use a small screwdriver in order to press in the retainer springs. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. Page 2599 The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. See: Testing and Inspection/Diagnostic Trouble Code Descriptions DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. NOT RUN SCC (NOT RUN SINCE CODE CLEAR): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Page 2979 Evaporative Emission (EVAP) Canister Purge Solenoid Page 288 Sunroof Switch Page 9788 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 6337 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 173 Powertrain Control Module (PCM) Page 5117 Abbreviations And Meanings - Part 10 Service and Repair Window Track: Service and Repair Window Run Channel Replacement Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the bolts that retain the front run channel to the door. 4. Carefully pull the front run channel in order to disengage the run channel from the window weatherstrip. 5. Remove the front run channel from the door. 6. Slide the window forward. 7. Remove the bolts that retain the rear run channel to the door. 8. Carefully pull the front run channel in order to disengage the run channel from the window weatherstrip. 9. Remove the rear run channel from the door. Installation Procedure 1. Install the rear run channel to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the rear run channel to the door. Tighten the bolts to 10 N.m (88 lb in). 3. Slide the window rearward into the rear run channel. 4. Install the front run channel to the door. 5. Install the bolts that retain the front run channel to the door. Tighten the bolts to 10 N.m (88 lb in). 6. Install the water deflector. 7. Install the door trim panel. Page 8116 6. Install the console compartment insert. 7. Install the console compartment insert screws. Tighten Tighten the nuts to 1.9 N.m (17 lb in). 8. Install the shift handle to the shift lever. 9. Install the shift handle retaining clip at the front of the handle. Console Replacement - Front Floor (Full Length (Envoy) Console Replacement - Front Floor (Full Length (Envoy)) Removal Procedure 1. Remove the front ashtray from console by gently prying out the ashtray with a flat-bladed tool. 2. Carefully lift up on the wood shifter assembly close-out in order to remove the assembly from the console. The closeout panel will need to be Page 2799 Engine Control Module: Description and Operation Vehicle/Powertrain Control Module & the BCM VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(tm) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 3584 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 1989 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 5701 C403 (Body Harness To LH Tail Lamp Harness) (Domestic) Page 3208 Engine Harness Rear (4.3L) Page 1628 Drive Belt Whine Diagnosis Step 1 - 5 Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The number(s) refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Page 6792 Air Bag Control Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Page 746 Page 4991 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 621 Disclaimer Page 3237 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 7486 Speaker - RF Page 9388 Abbreviations And Meanings - Part 1 Page 6172 Notice: Refer to Fastener Notice in Service Precautions. 6. Install the to the stabilizer shaft link retaining nut to the stabilizer shaft link bolt until the nut meet the end of the bolt threads. Tighten the stabilizer shaft link retaining nut to 18 Nm (13 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. Page 8637 Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 122 Cruise Control Module (CCM) Part 2 Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 9438 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 986 3. Observe the drive belt routing for the vehicles with air conditioning. 4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 5. Install the drive belt over the drive belt tensioner pulley. 6. Slowly release the tension on the drive belt tensioner arm. 7. Inspect for the drive belt being properly installed on the pulleys. Page 6470 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 9087 Page 8711 Registered And Non-Registered Trademarks - Part 4 Page 5113 Abbreviations And Meanings - Part 6 Page 3558 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SM Caution In Service Precautions. 1. Disable the SIR system. 2. Remove the steering column trim covers. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. Page 3387 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 1067 Power Steering Line/Hose: Service and Repair Power Steering Pressure Hose Power Steering Pressure Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the steering linkage shield, if equipped. 3. Install a drain pan under the vehicle. 4. Disconnect the pressure hose from the power steering pump. 5. Lower the vehicle. 6. Remove the air cleaner assembly. 7. Disconnect the power steering gear pressure hose from the power steering gear. 8. Remove the power steering gear pressure hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Page 5032 Abbreviations And Meanings - Part 21 Page 302 Rear Window Wiper Cutout And Liftglass Ajar Jamb Switch (Utility) Page 7857 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the fasteners that retain the latch assembly to the door. Tighten the fasteners to 9 N.m (80 lb in). 4. Connect the power actuator wiring connector, if equipped. 5. Install the outside door handle rod to the latch assembly. 6. Install the inside door handle rod to the latch assembly. 7. Install the inside door lock rod (1) to the latch assembly. 8. Install the water deflector. 9. Install the door trim panel. Page 4552 Page 8329 WA519F/12 - WA519F/12 Page 543 Heated Oxygen Sensor (HO2S), Bank 2 Sensor 1 Page 9823 Abbreviations And Meanings - Part 9 Locations Engine, LR Page 9850 Door Lock And Window Switch - Front Passenger C1 Part 1 Locations Inflatable Restraint Steering Wheel Module/Horn Pad Page 2463 4. Using a long screw driver, align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine. 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. - There may be a 6 cast into this pointer, indicating that the distributor is to be used on a 6 cylinder engine or an 8, indicating that the distributor is to be used on a 8 cylinder engine. - If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more. - If this is the case, repeat the procedure again in order to achieve proper alignment. 7. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 8327 WA387E/57 - WA408G/44 Page 4491 6. Install the brake caliper bolts. Tighten the brake caliper bolts to 31 Nm (23 ft. lbs.). 7. Install the NEW metal (copper) gaskets to the brake hope and the bolt. Notice: Refer to Brake Hose Installation Notice in Service Precautions. 8. Install the rear brake hose bolt. Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Page 5505 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 5264 C211 (Steering Column Harness To Body Harness) Part 3 Page 4507 5. Using J26267, install the front caliper piston boot.. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bleeder valve. Tighten the bleeder valve to 12 Nm (110 inch lbs.). Brake Caliper Overhaul - Front (Dual Piston) Brake Caliper Overhaul - Front (Dual Piston) Tools Required ^ J8092 Driver Handle ^ J43885 Boot Seal Installer Disassembly Procedure 1. Drain all the brake fluid from the caliper. 2. Install a piece of wood or shop towels between the piston and the inside of the brake caliper. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 8332 WA528F/76 - WA5322/33 Page 3298 For vehicles repaired under warranty, use the table. Disclaimer Page 1220 Fuse Block - Underhood Connector C2 Part 3 Page 6726 A/C Low Pressure Switch Page 5037 Abbreviations And Meanings - Part 26 Page 9648 Registered And Non-Registered Trademarks - Part 2 Page 1058 4. Install the J 44551 -5 screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551 -5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. IMPORTANT:Correct placement of J 44551 -5 is critical. 6. Remove the J 44551 -5 suction screen tool from the suction hose. 7. Install an A/C refrigerant filter. IMPORTANT:After a major compressor failure, you should also install an A/C refrigerant filter. 8. Install the J 44551 -1 suction screen notification label. Replacement SUCTION SCREEN REPLACEMENT TOOLS REQUIRED - J 42220 Universal Leak Detection Lamp - J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the A/C compressor hose assembly bolt. 3. Separate the A/C compressor hose assembly from the A/C compressor. 4. Select the proper size removal tool (1) from J 44551. IMPORTANT:The suction screens are available in 3 different sizes. 5. Remove the suction screen using the J 44551 -31 suction screen removal tool. 5.1. Thread the forcing screw into the suction screen. 5.2. Tighten the nut on the forcing screw to remove the suction screen. Page 2500 Body Control Module (BCM) C2 Part 2 Page 8337 WA722J/25 - WA765J/37 Page 2071 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Using the J 38185 reposition the radiator outlet hose clamp from the radiator. 3. Using the J 38185 reposition the radiator outlet hose clamp from the water pump. 4. Remove the radiator outlet hose. Installation Procedure Service and Repair Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve Replacement Removal Procedure 1. Disconnect the Positive Crankcase Ventilation (PCV) valve hose assembly from the intake manifold. 2. Disconnect the PCV valve hose from the valve rocker arm cover. 3. Turn and remove the PCV valve cover from the upper intake manifold. 4. Remove and discard the seal (O-ring). Installation Procedure Page 826 Door Lock And Window Switch - Driver C2 Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 1047 12. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Locations Instrument Panel Details, RH Locations LF Front Fender Area Page 1880 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Page 593 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 5115 Abbreviations And Meanings - Part 8 Page 6313 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 615 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Service and Repair Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 1723 4. Remove the oil pan. 5. Remove the oil pan gasket. 6. Discard the oil pan gasket. 7. Clean all sealing surfaces on the engine and the oil pan. Installation Procedure Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. 1. Apply a 5 mm (0.197 inch) wide and 25 mm (1.0 inch) long bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces. Description and Operation Fuel Meter Body: Description and Operation FUEL METER BODY ASSEMBLY The fuel meter body assembly (1) attaches to the lower intake manifold. The fuel meter body assembly performs the following functions: - Distributes fuel evenly to the injectors (3) - Integrates the fuel pressure regulator (6) into the fuel metering system. Page 5266 C211 (Steering Column Harness To Body Harness) Part 5 Page 2338 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 1978 Maximum fan speed (air flow and related fan noise) through the engine compartment is experienced under two conditions. 1. When the vehicle sits in an unused condition for several hours, the viscous fluid within the thermostatic fan clutch assembly migrates and fully engages the clutch of the fan. After a short drive, the viscous fluid will migrate to the storage area in the fan clutch and the fan clutch will slip, reducing the noise (roar of the fan). This is normal thermostatic fan clutch operation. 2. When the engine is running, and the air being drawn by the fan or pushed through the radiator from the vehicle movement reaches a high enough temperature, the fan clutch will fully engage the fan clutch, drawing additional air through the radiator to lower the engine coolant temperature and A/C refrigerant temperature. When the cooling fan clutch fully engages, fan noise increases (for example; this is the same as switching an electric household fan from low to high speed). Some customers have interpreted this sound increase to be an increase in the engine RPM due to transmission downshift, transmission slipping, or TCC cycling. As the engine coolant temperature decreases, the fan clutch will begin to slip, lowering the actual speed of the fan blade and the resultant sound. Service Procedure When diagnosing an intermittent transmission downshift, slip, or busy/cycling TCC, follow these steps: 1. Verify the transmission fluid level and the fluid condition. Refer to the Automatic Transmission sub-section of the appropriate Service Manual. 2. Test drive the vehicle under the conditions described by the customer (ambient temperature, engine coolant temperature, trailering, etc.). It may be necessary to partially restrict airflow to the radiator in order to raise the engine coolant temperature to match the customer's conditions. 3. Monitor the engine RPM and the engine coolant temperature using a scan tool. 4. Listen for an actual increase in the engine RPM. Use either the vehicle tachometer (if equipped), the Tech 2 RPM or transmission slip speed as an indicator, rather than just the sound. If the engine RPM display on the tachometer or the Tech 2 increases, verify the scan tool RPM and coolant temperature readings. If the noise increase is due to the engagement of the fan, the engine RPM will not increase and the engine coolant temperature will begin to decrease after the fan engages. As the fan runs, the engine coolant temperature will drop and the fan will disengage, reducing noise levels. The engine RPM will not decrease. This cycle will repeat as the engine coolant temperature rises again. If the above procedure shows the condition to be cooling fan-related, no further action is necessary. The vehicle should be returned to the customer and the condition explained. If the above procedure shows the condition to be other than cooling fan-related, refer to the Automatic Transmission sub-section of the appropriate Service Manual for transmission diagnosis information. The following information regarding the operation of the engine cooling fan should be photocopied and given to the customer. Intermittent Transmission Downshift All light duty trucks are equipped with a thermostatic engine cooling fan. This fan is designed to provide greater fuel efficiency and quieter operation than a standard fan. These benefits are possible through the addition of a thermostatic clutch to the fan drive. When the engine is cool (it the engine has been run in the last few hours), the clutch allows the fan to "slip" or turn at a speed slower than the engine. By turning at a slower speed, the fan uses less horsepower, which saves fuel, and is quieter. When the engine temperature reaches a preset temperature or if the engine has not been run for several hours, the fan "engages" and turns at the same speed as the engine. "Engagement" of the fan provides increased airflow through the radiator to cool the engine. As the airflow increases, fan operation becomes clearly audible. This increase in noise can easily be mistaken for an increase in engine RPM and may be incorrectly blamed on the automatic transmission. When operating an unloaded vehicle in cooler ambient temperatures, the thermostatic clutch usually won't fully engage. However, if the vehicle is pulling a trailer, is heavily loaded or is operated at high ambient temperatures, the thermostatic fan clutch may cycle on and off as the engine coolant temperature rises and falls. The sound of fan operation under the conditions described above is a sign that the cooling system on your vehicle is working correctly. Replacement or modification of the cooling system or the transmission parts will not change or reduce the noise level. Attempts to reduce this noise may cause you, the customer, to believe that your vehicle is not reliable and will inconvenience you by causing your vehicle to be out of service. Page 4627 Brake Caliper: Service and Repair Brake Caliper Replacement - Front (Dual Piston) Brake Caliper Replacement - Front (Dual Piston) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper hose bolt from the brake caliper. 4. Remove the 2 copper gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 5. Discard the 2 copper gaskets. 6. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 7. Remove the brake hose and washers from the brake caliper. 8. Remove the brake caliper guide pin bolts. Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 1664 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the right exhaust manifold. 3. Remove the oil level indicator tube bolt. 4. Remove the oil level indicator tube from the engine using a twisting motion. 5. Clean the old sealer from the oil level indicator tube and the engine block. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent around the oil level indicator tube 13 mm (0.5 inch) below the tube bead. Page 2688 Abbreviations And Meanings - Part 8 Page 3819 7. If the vehicle is equipped with a 2.2L engine, proceed to step 9. 8. Install the rear output shaft. 9. Install the exhaust manifold pipe. 10. Lower the vehicle. 11. If the vehicle is equipped with a 2.2L engine, install the bolt securing the dipstick to the exhaust manifold. 12. Install the bolts securing the oil level indicator tube to the engine. ^ Tighten the bolts to 47 Nm (35 ft. lbs.). 13. Install the transmission oil level indicator. 14. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 294 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement With RPO Code CF5 SUNROOF SWITCH REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the driver information console (DIC). 2. Disconnect the electrical connector from the driver information display module. 3. Remove 6 screws securing the sunroof switch assembly to the DIC. 4. Remove the sunroof switch assembly from the DIC. INSTALLATION PROCEDURE Page 2775 Body Control Module (BCM) C3 Part 2 Page 6065 Equivalent - Decimal And Metric Part 2 Page 7688 Abbreviations And Meanings - Part 16 Page 2217 Page 1434 Disclaimer Page 3870 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side Page 542 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 2 Page 7076 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 273 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. 2. Connect the electrical connector to the switch. 3. Install the trim panel to the seat with the 3 screws. 4. Install the seat to the vehicle. Page 757 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6093 Abbreviations And Meanings - Part 16 Page 6125 1. Connect the tie rod ends to the adjuster tube. Ensure that the number of threads on both the inner and the outer tie rod ends are equal within three threads. 2. Install the inner tie rod ball stud to the relay rod. Ensure that the seal is on the stud. Notice: Refer to Fastener Notice in Service Precautions. 3. Seat the taper using J 29193 or J 29194. Tighten J 29193 or J 29194 to 54 Nm (40 ft. lbs.). 4. Remove J 29193 or J 29194 from inner tie rod ball stud. 5. Install the new nut to the inner tie rod ball stud. Tighten the inner tie rod ball stud nut to the relay rod to 47 Nm (35 ft. lbs.). 6. Connect the outer tie rod ball stud to the steering knuckle. Ensure that the seal is on the stud. 7. Seat the taper using J 29193 or J 29194. Tighten J 29193 or J 29194 to 54 Nm (40 ft. lbs.). 8. Remove J 29193 or J 29194 from outer tie rod ball stud. 9. Install the nut to the outer tie rod ball stud. Page 7729 Body Control Module (BCM) C1 Part 3 Diagrams Ambient Air Temperature Sensor (DIC) Page 4986 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 9469 Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt ..................................................................................................................... ..................................................... 95 Nm (70 ft. lbs.) Crankshaft Balancer Remover/Installer Bolt ............................................................................................................................................ 25 Nm (18 ft. lbs.) Crankshaft Pulley Bolt ............................................................................................................. ................................................................. 58 Nm (43 ft. lbs.) Page 9132 Abbreviations And Meanings - Part 10 Page 7494 Speaker: Service and Repair Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR TOOLS REQUIRED J 34940 Rivet Gun REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the speaker retaining rivets. 3. Remove the front side door speaker. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the radio front side door speaker. 3. Install the speaker retaining rivets using J 34940. 4. Install the door trim panel. 5. Inspect for proper circuit operation. Page 1854 Steps 15-17 Page 6606 HVAC Control Assembly C4 Page 9719 Abbreviations And Meanings - Part 9 Page 648 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 2644 Page 3450 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side Page 4326 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 8380 WA805K/62 - WA810K/48 Page 8105 5. Remove the transmission select switch (if equipped). 6. Remove the nuts that retain the rear of the console. 7. Remove the cup holder insert. 8. Remove the screws that retain the front of the console to the vehicle. 9. Remove the console from the vehicle. INSTALLATION PROCEDURE Page 9704 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Locations Electronic Components Page 8212 1. Remove the upper and lower rear seat belt anchor bolts. 2. Remove the endgate or the liftgate opening door sill trim plate. 3. Remove the jack storage cover (driver side only). 4. Remove the screws that retain the body side trim panel to the vehicle (driver side only). 5. Remove the spare tire and the carrier assembly (if equipped). 6. Remove the left and right body side trim panel from the vehicle. 7. Feed the seat belt through the trim panel. Installation Procedure 1. Install the body side trim panel to the vehicle. 2. Feed the seat belt through the trim panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the body side trim panel to the vehicle (left side only). Tighten the screws to 1.9 N.m (17 lb in). 4. Install the spare tire and the carrier assembly (if equipped). 5. Install the jack storage cover (left side only). 6. Install the endgate or liftgate opening door sill trim plate. 7. Install the upper and lower rear seat belt anchor bolts. * Tighten the upper bolts to to 70 N.m (52 lb ft). * Tighten the lower bolts to to 80 N.m (59 lb ft). Trim Panel Replacement - Body Side (4-Door) TRIM PANEL REPLACEMENT - BODY SIDE (4-DOOR UTILITY) REMOVAL PROCEDURE Page 3746 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 5384 Splice Pack SP204 Part 2 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 396 Page 1022 5. Install the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 6660 7. Place the heater inlet hose in the retaining clip above the right side valve cover. 8. Close the retaining clip. Ensure that the clip locks. 9. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Body Relay Block Page 5872 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 436 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 7235 Page 7804 5. Install the outside door handle rod (2) to the latch assembly. 6. Install the outside lock rod (1) to the latch assembly. 7. Install the inside door handle rod (2) to the latch assembly. 8. Install the inside door lock rod to the latch assembly (1). 9. Install the water deflector. 10. Install the door trim panel. Page 6183 12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position. 13. Position the balance shaft drive gear onto the engine camshaft. 14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned. 15. Install the timing chain and the camshaft sprocket. 16. Install the engine front cover. 17. Install the valve lifter pushrod guide. 18. Install the A/C condenser. 19. Install the radiator. Page 9396 Abbreviations And Meanings - Part 9 Page 1640 Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Refer to Engine Mounting Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Inspect for loose or missing bolts at the following locations: ^ The engine mount to the engine ^ The engine mount to the engine mount frame bracket through-bolts ^ The engine mount frame bracket to the frame 3. Replace missing or loose bolts. Notice: Refer to Engine Lifting Notice in Service Precautions. 4. In order to access the square tab on the right side of the engine remove the starter. Using a jack on the square tab at the rear of the engine block (left side shown the right side requires removal of the starter) raise the engine in order to complete the following tasks: ^ Remove weight from the engine mount. ^ Place a slight tension on the rubber cushion. ^ Observe the engine mount while raising the engine. 5. Replace the engine mount if the following conditions exist: ^ Heat check cracks cover the hard rubber surface. ^ The rubber cushion is separated from the metal plate of the engine mount. ^ There is a split through the rubber cushion. ^ Replace the starter, if removed. 6. Lower the vehicle. Page 6051 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 5021 Abbreviations And Meanings - Part 10 Page 9537 Inside Rearview Mirror (W/ Automatic Day/Night Mirror) Page 2643 Page 2072 1. Install the radiator outlet hose. 2. Using the J 38185 reposition the radiator outlet hose clamp to the water pump. 3. Using the J 38185 reposition the radiator outlet hose clamp to the radiator. 4. Fill the cooling System. Page 7828 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Door Opening Weatherstrip Replacement - Door Opening Removal Procedure 1. Remove the door opening weatherstrip from the door opening. 2. Gently pull the weatherstrip from the pinch weld flange. Installation Procedure 1. Install the door opening weatherstrip to the door opening. 2. Position the pre-formed corner of the weatherstrip in the upper rear corner of the door opening. 3. Push the weatherstrip onto the pinch weld flange. Start at the pre-formed corner and work around the entire edge of the door opening. Page 1046 3. Install the heater outlet hose to the water pump. 4. Install the heater outlet hose clamp using the J 38185 at the water pump. 5. Install the heater inlet hose to the intake manifold fitting. 6. Install the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 7. Install the outlet heater hose to the heater core. 8. Install the outlet heater hose clamp using the J 38185 at the heater core. 9. Install the heater outlet hose to the retaining clip at the engine water outlet. 10. Place the outlet heater hose in the retaining clip above the right side valve cover. 11. Close the retaining clip. Ensure that the clip locks. Page 360 Engine Coolant Temperature (ECT) Sensor Page 7654 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 3459 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 2160 4. Slide the PCM retainer into the PCM bracket slots. 5. Pull the PCM retention bar into position. Page 4888 Equivalent - Decimal And Metric Part 2 Page 9416 Registered And Non-Registered Trademarks - Part 2 Page 7114 Abbreviations And Meanings - Part 7 Page 5191 Relay Block - Body Part 1 Page 6486 Equivalent - Decimal And Metric Part 1 Page 3285 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 9474 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 8909 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. 3. Test the circuit operation. Page 8124 5. Install the transmission select switch (if equipped). 6. Install the console compartment insert. 7. Install the console compartment insert screws. Tighten the nuts to 1.9 N.m (17 lb in). 8. Install the shift handle to the shift lever. 9. Install the shift handle retaining clip at the front of the handle. Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and Description and Operation Glove Compartment Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Page 2376 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Page 9691 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 3195 4. Separate the air cleaner outlet duct from the air cleaner by loosening the hose clamp after the mass air flow (MAF) sensor. 5. Remove air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install air cleaner outlet duct to throttle body. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. 2. Install air cleaner outlet duct to MAF sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the hose clamp to 4 N.m (35 lb in). 3. Connect the IAT sensor harness connector. Page 9460 Page 4586 10. Install the brake shoe guide. 11. Install the brake shoe return springs. 12. Install the brake drum. 13. Install the tire and wheel assembly. 14. Adjust the brakes. Page 4821 Clutch Switch: Service and Repair Clutch Start Switch Replacement Removal Procedure 1. Remove the plastic retainer tabs from the clutch start switch. 2. Remove the clutch start switch from the push rod. 3. Remove the connector from the switch. Installation Procedure 1. Install the connector to the clutch start switch switch. 2. Install the clutch start switch to the pushrod with the plastic tabs. 3. Install the push rod to the clutch pedal. Page 5738 C204 (Floor Shifter Harness To Body Harness) (Utility and Crew Cab) Page 6087 Abbreviations And Meanings - Part 10 Page 5279 C305 (Body Harness To LR Door Harness) (4-Door) Page 7270 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8805 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolts that retain the endgate torque rod bracket to the vehicle body. Tighten the bolts to 10 N.m (88 lb in). OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 395 Page 8269 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws (2) that retain the actuator (1) to the latch. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the latch to the door. 6. Install the water deflector. 7. Install the door trim panel. Page 2148 Powertrain Control Module (PCM) Connector C1 Part 4 Page 4512 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front brake pads, outboard shown. 4. Remove the front brake caliper bracket mounting bolts, lower shown. 5. Remove the front brake caliper mounting bracket. Installation Procedure Page 2789 Powertrain Control Module (PCM) Connector C1 Part 3 Locations Locations View Page 4596 Brake Shoe: Adjustments Drum Brake Adjustment Tools Required ^ J21177-A Drum to Brake Shoe Clearance Gauge Important: The rear brakes must be adjusted manually after replacing the rear brake shoes. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the brake drum. Fig. 7 Measuring Brake Drum Inside Diameter 3. Using the J21177-A measure the inside diameter of the brake drum. Important: When performing the following service procedure, ensure that the J21177-A is level before taking the measurement. Fig. 8 Adjusting Brake Shoes To Brake Drum Inside Diameter 4. Using the J21177-A, adjust the brakes shoes until there is approximately 0.50 mm (0.020 lbs.) clearance between the rear brake shoes and the rear brake drum. Page 8264 5. Install the latch to the door. 6. Install the water deflector. 7. Install the door trim panel. Lock Actuator Replacement - Rear Door LOCK ACTUATOR REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws (2) that retain the lock actuator (1) to the latch. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. INSTALLATION PROCEDURE Page 7318 NON-COMPATIBLE GARAGE DOOR OPENERS Page 7079 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 5498 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Locations Shift Solenoid: Locations Steering Column Components Testing and Inspection Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids Inspect the connectors at the BCM, and all other circuit connecting points for an intermittent condition. Inspect the circuit wiring for an intermittent condition. If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Page 3182 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Page 9346 Page 4118 Clutch Switch: Service and Repair Clutch Start Switch Replacement Removal Procedure 1. Remove the plastic retainer tabs from the clutch start switch. 2. Remove the clutch start switch from the push rod. 3. Remove the connector from the switch. Installation Procedure 1. Install the connector to the clutch start switch switch. 2. Install the clutch start switch to the pushrod with the plastic tabs. 3. Install the push rod to the clutch pedal. Page 5750 C223 (IP Harness To Auxiliary Power Tray) (Extended Cab) Page 5354 C403 (Body Harness To LH Tail Lamp Harness) (Domestic) Seal Replacement - Hood Front Hood Weatherstrip: Service and Repair Seal Replacement - Hood Front Seal Replacement - Hood Front Removal Procedure 1. Use a flat-bladed tool in order to carefully pry the seal assembly away from the flange. 2. Remove the seal from the hood. Installation Procedure 1. Position the seal assembly to the hood. 2. Press the seal assembly into place until fully seated. Locations Power Trunk / Liftgate Lock Actuator: Locations Liftglass Release Actuator Page 3462 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Page 2929 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 8712 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 107 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the straps that retain the wiring harness. 3. Disconnect the electrical connectors, as needed. 4. Slide the sunroof control module (2) to the right in order to remove the sunroof control module from the vehicle. INSTALLATION PROCEDURE 1. Slide the sunroof control module (2) to the left in order to install the sunroof control module to the vehicle. 2. Connect the electrical connectors, as needed. 3. Install the straps that retain the wiring harness. 4. Install the headliner. Page 2699 Abbreviations And Meanings - Part 19 Page 5410 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 5028 Abbreviations And Meanings - Part 17 Seal Replacement - Hood Front Hood Weatherstrip: Service and Repair Seal Replacement - Hood Front Seal Replacement - Hood Front Removal Procedure 1. Use a flat-bladed tool in order to carefully pry the seal assembly away from the flange. 2. Remove the seal from the hood. Installation Procedure 1. Position the seal assembly to the hood. 2. Press the seal assembly into place until fully seated. Page 5783 C501 (Body Harness To LH Front Door Harness) (4-Door) Part 2 Body Relay Block Page 7303 Registered And Non-Registered Trademarks - Part 2 Page 7165 For vehicles repaired under warranty use, the table. Disclaimer Page 7338 Disclaimer Page 7358 Disclaimer Page 6475 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 8224 Door Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Door Removal Procedure New lock cylinders are available as replacement components. When you replace a lock cylinder, apply a coating of appropriate lubricant inside the lock case and the cylinder keyway prior to installing the cylinder. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. In order to repair a binding lock cylinder, refer to Binding Lock Cylinders. In order to code a new lock cylinder, refer to Key and Lock Cylinder Coding in General Information. 1. Remove the outside door handle. 2. Use a flat-bladed tool in order to remove the door lock cylinder retainer. 3. Remove the door lock cylinder from the outside door handle. Installation Procedure 1. Install the door lock cylinder to the outside door handle. 2. Install the door lock cylinder retainer. 3. Install the outside door handle. With Air Conditioning With A/C Page 3278 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 3094 Steps 5-7 Page 8615 Disclaimer Page 3000 2. Connect the EVAP pipe to the EVAP canister purge valve. Page 4934 Alternator: Description and Operation The CS130 generator is non-repairable. They are electrically similar to earlier models. The generator feature the following major components: - The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The CS stands for Charging System, the 30 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generator is rated at 100 amps. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is ,replaced as a complete unit. Page 8952 Page 1614 Page 6734 Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Remove the blower motor relay (1) from the retaining bracket. 3. Disconnect the electrical connector. 4. Remove the blower motor relay. INSTALLATION PROCEDURE 1. Install the blower motor relay. 2. Connect the electrical connector. 3. Install the blower motor relay (1) to the retaining bracket. 4. Connect the negative battery cable. Spring Shackle Replacement Shackle: Specifications Spring Shackle to Frame Nut 89 ft. lbs. Spring Shackle to Leaf Spring Nut 89 ft. lbs. Page 5747 C211 (Steering Column Harness To Body Harness) Part 5 Page 344 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 4642 2. Install the brake caliper bolts to the mounting bracket. Tighten the brake caliper bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Installing Hoses without Twists or Bends Notice in Service Precautions. Important: When performing the following service procedure, DO NOT reuse the old bolt washers. Always use new washers. 3. Install the brake hose bolt and washers. Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 4. Fill the brake master cylinder to the proper level. 5. Bleed the brake calipers. 6. Install the tire and wheel assembly, 7. Lower the vehicle. Refer to Vehicle Lifting. Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Page 3357 Ignition Control Module: Description and Operation IGNITION COIL AND ICM The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Service and Repair Auxiliary Step / Running Board: Service and Repair Assist Step Replacement (ZR5 ) Removal Procedure 1. Remove 8 nuts (1) and 4 U-bolts (3) securing the assist step assembly to the mounting brackets. 2. Remove the 11 nuts (2) and 4 brackets. 3. Remove the plastic end caps from the assist step assembly if required. 1. Remove the 3 screws from the assist step assembly. 2. Remove the plastic end cap by pulling the cap straight out of the step assembly. 4. Remove the plastic step pads if required by breaking the plastic pad from the assist step assembly. Installation Procedure 1. Install new plastic step pads to the assist step assembly by pressing the new pad into place. 2. Install the plastic end cap to the assist step assembly. 1. Install the plastic end cap by pressing the cap straight into the assist step assembly. 2. Install 3 screws into the step assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 brackets and 11 nuts (2). Tighten to 35 N.m (26 lb ft). 4. Install the assist step assembly to the mounting brackets with 4 U-bolts (3) and 8 nuts (1). Tighten the step assembly nuts to 20 N.m (15 lb ft). Page 1410 The smearing of the metal is due to slippage. Slippage can be caused by the following factors: ^ Poor fits ^ Lubrication ^ Overheating ^ Overloads ^ Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Page 4190 Flywheel: Specifications Engine Flywheel Bolt ........................................................................................................................... .................................................. 100 Nm (74 ft. lbs.) Page 9680 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 5854 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Locations Shift Solenoid: Locations Steering Column Components Page 4813 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (RWD Utility) Wheel Speed Sensor Replacement (RWD Utility) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. 9. Remove wheel speed sensor from hub and bearing assembly (5). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 2714 Information Bus: Electrical Diagrams Power, Ground, and Transfer Case Shift Control Module Page 1835 For vehicles repaired under warranty, use the table. Disclaimer Page 3153 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Disconnect the chassis fuel feed and return pipes (1) at the engine compartment fuel feed and return pipes. 4. Remove the transmission. 5. Remove the fuel pipe retainer clip (2) from the left cylinder head. 6. Disconnect the fuel feed pipe (3) and the fuel return pipe (2). 7. Remove the fuel feed and return pipes. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. Page 9014 Abbreviations And Meanings - Part 26 Page 7795 Front Door Interior Handle: Service and Repair Door Handle Components Handle Bezel Replacement - Inside Removal Procedure 1. Remove the screw that retains the front inside door handle bezel to the door trim panel. 2. Remove the screw that retains the rear inside door handle bezel to the door trim panel. 3. Remove the inside door handle bezel from the door trim panel by sliding rearward. Installation Procedure 1. Route the inside door handle and the lock rod through the appropriate openings in the bezel. 2. Align the lock rod to the door lock knob. 3. Position the bezel and snap the bezel into place. 4. Install the rear inside door handle bezel to the door trim panel. 5. Install the front inside door bezel to the door trim panel. Notice: Refer to Fastener Notice in Service Precautions. 6. Insert the screw that retains the inside door handle bezel to the door trim panel. Page 9294 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 9517 Abbreviations And Meanings - Part 13 Page 4628 9. Remove the brake caliper assembly. Installation Procedure 1. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake caliper bolts to the mounting bracket. Tighten the brake caliper bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Installing Hoses without Twists or Bends Notice in Service Precautions. Important: When performing the following service procedure, DO NOT reuse the old bolt washers. Always use new washers. Page 7701 Registered And Non-Registered Trademarks - Part 2 Page 6108 Registered And Non-Registered Trademarks - Part 4 Locations Floor Pedals Page 4981 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door Tools Required J 34940 Rivet Gun Removal Procedure Important: The rear door power window motor and regulator replacement parts are sold as an assembly. Do not attempt to separate the motor from the regulator before verifying that separate replacement parts are available. 1. Remove the window. 2. Disconnect the power window motor electrical connector, if equipped. 3. Remove the electrical harness retainers, if equipped. 4. Drill out the rivets that secure the window regulator to the door. 5. Remove the window regulator and the motor assembly (power windows only) from the door. Installation Procedure 1. Install the window regulator and the motor assembly (power windows only) to the door. 2. Install the rivets that secure the window regulator to the door using J 34940. 3. Install the electrical harness retainers, if equipped. 4. Install the power window motor electrical connector, if equipped. 5. Install the window. Page 4443 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 7137 Registered And Non-Registered Trademarks - Part 3 Page 8661 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 6098 Abbreviations And Meanings - Part 21 Page 8662 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7437 Page 6007 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Page 2127 Body Control Module (BCM) C1 Part 2 Page 7431 Page 5346 C305 (Body Harness To LR Door Harness) (4-Door) Page 7653 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 3271 Disclaimer Page 8113 Console: Service and Repair Console Replacement - Front Floor (Full Length (Auto Trans) CONSOLE REPLACEMENT - FRONT FLOOR (FULL LENGTH (AUTO TRANS)) REMOVAL PROCEDURE 1. Remove the shift handle retaining clip at the front of the handle. 2. Remove the shift handle from the shift lever. 3. Open the console lid. 4. Remove the console compartment inserts. Page 9263 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Page 8800 Air Dam: Service and Repair Air Intake Baffle Replacement - Radiator Air Intake Baffle Replacement - Radiator Removal Procedure 1. Remove the radiator grille. 2. Remove the outside air temperature sensor. 3. Remove the radiator air intake baffle retainers. 4. Remove the radiator air intake baffle. Installation Procedure 1. Install the radiator air intake baffle. 2. Install the radiator air intake baffle retainers. 3. Install the outside air temperature sensor. 4. Install the radiator grille. Locations Oxygen Sensor: Locations Heated Oxygen Sensors (HO2S) Page 7528 For vehicles repaired under warranty, use the table. Disclaimer Page 5343 C302 (Power Seat Harness, LH To Power Recliner Harness, LH) (w/ Power Seats, Memory) Instrument Panel - Right Air Register: Service and Repair Instrument Panel - Right AIR OUTLET REPLACEMENT - INSTRUMENT PANEL - RIGHT REMOVAL PROCEDURE 1. Remove the instrument panel carrier. 2. Remove the air distribution duct. 3. Remove the screw (1) securing the air outlet assembly to the instrument panel carrier. 4. Remove the air outlet assembly from the instrument panel carrier. INSTALLATION PROCEDURE 1. Install the air outlet assembly into the instrument panel carrier. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 5263 C211 (Steering Column Harness To Body Harness) Part 2 Page 8515 Sunroof / Moonroof Wiring Harness: Service and Repair Sunroof Wiring Harness Replacement RPO Code Zrx/Extreme W/CF5 SUNROOF WIRING HARNESS REPLACEMENT WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. Remove the 15A fuse from the sunroof fused jumper wire at the lower fuse block. 2. Remove the sunroof panel window garnish molding (3). 3. Disconnect the sunroof power feed connector (1) at the front header. 4. Remove the LF windshield pillar garnish molding. 5. Remove the LF sunshade and retainer. Page 3813 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Locations Low Pressure Sensor / Switch: Locations A/C Accumulator Page 9711 Abbreviations And Meanings - Part 1 Page 4164 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 8216 1. Remove the rear door sill trim plate. 2. Remove the lower rear seat belt bolt. 3. Remove the body side lower trim panel from the vehicle. Installation Procedure 1. Install the body side lower trim panel to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower seat belt bolt. Tighten the bolt to 70 N.m (52 lb ft). 3. Install the rear door sill trim plate. Page 5400 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 9725 Abbreviations And Meanings - Part 15 Page 9825 Abbreviations And Meanings - Part 11 Page 1514 12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position. 13. Position the balance shaft drive gear onto the engine camshaft. 14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned. 15. Install the timing chain and the camshaft sprocket. 16. Install the engine front cover. 17. Install the valve lifter pushrod guide. 18. Install the A/C condenser. 19. Install the radiator. Page 4886 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 5824 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 7600 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Locations Cabin Air Filter: Locations This vehicle does not use a factory installed Cabin Air Filter. Page 9117 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 266 Seat Lumbar Switch - Driver Part 1 Page 3472 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 289 Sunroof Switch C2 Page 7370 Diagnostic Tips Review Table Page 664 Seat Belt Switch - LF Page 2128 Body Control Module (BCM) C1 Part 3 Page 6471 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 5134 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Description and Operation Door Switch: Description and Operation DOOR LATCH, DOOR JAMB SWITCHES The theft deterrent system uses the door latch switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. Page 6030 Page 8339 WA800J/98 - WA805K/62 Page 9631 Abbreviations And Meanings - Part 12 Locations Endgate Harness Routing View Page 2888 Intake Air Temperature (IAT) Sensor Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4400 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORX mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the E13CM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TOW screws (1) in the EBCM (2). Tighten the four T-25 TOW screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). Page 9608 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 6603 Control Assembly: Diagrams HVAC Control Assembly C1 Page 5309 C117 (Engine Harness To AIR Harness, w/ California Emissions) Page 4563 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Notice: Refer to Brake Caliper Notice in Service Precautions. 3. Remove the hub and bearing assembly. 4. Remove the splash shield. Installation Procedure 1. Install the splash shield. 2. Install the hub and bearing assembly. 3. Install the tire and wheel assembly. 4. Lower the vehicle. 5. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 6. Slowly release the brake pedal. 7. Wait 15 seconds, then repeat steps 5-6 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Page 8198 6. Remove the 8 garnish molding screws. 7. Remove the sunroof panel window garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Position the garnish molding to the headliner. 2. Ensure the sunroof switch wiring is positioned properly through the garnish molding. 3. Install one short front screw (1) and install one long rear screw in order to hold the garnish molding (3) in position. 4. Install the remaining screws including the one other short screw next to the motor/actuator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). Page 6814 Impact Sensor: Diagrams Inflatable Restraint Front End Discriminating Sensor - Left Page 1584 9. Install the heater hoses in the retainer above the valve rocker arm cover. 10. Install the Evaporative Emission (EVAP) canister purge solenoid valve. 11. Connect the spark plug wires to the spark plugs for the right side of the engine. 12. Install the PCV tube to the air cleaner outlet duct and the valve rocker arm cover. Page 8318 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Page 3264 Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement ^ Tools Required J 5825-A Crankshaft Gear Remover - J 5590 Crankshaft Gear Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both Sprockets line up. 4.2. The number four cylinder is at Top Dead Center (TDC) of the compression stroke. Page 3167 Tighten Tighten the fuel fill tube bracket retaining bolt to 15 N.m (11 lb ft). 4. Install the ground wire (5) to the frame crossover. Tighten Tighten the ground strap retaining screw to 15 N.m (11 lb ft). 5. Attach the ground wire to the lower fuel fill tube with new retaining straps (6). 6. Position the hose clamps (2, 7) on the upper (11) and lower (13) fuel fill hoses. Tighten Tighten the hose clamps (2, 7) to 2.5 N.m (22 lb in). 7. Install the spare tire (underbody mounted spare tire only). 8. Lower the vehicle. 9. Remove the fuel fill cap and refill the fuel tank. 10. Install the fuel fill cap. 11. Connect the negative battery cable. Page 9582 Description and Operation Cassette Features Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 5172 Fuse Block - Underhood Connector C1 Part 3 Page 4055 Page 8385 WA8554/40 - WA8554/40 Page 4569 5. Remove the brake rotor. 6. Inspect the brake rotor. 7. Refinish the brake rotor if necessary. Installation Procedure Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. Notice: Whenever the rotor has been separated from the axle flange, clean any rust or foreign material from the mating surface of the axle flange and brake rotor. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Using the J42450-A, clean the axle flange. 2. Install the brake rotor. Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolt ............................................................................................................................ ............................................... 12 Nm (106 inch lbs.) Page 4671 2. Install the brake caliper bolt to the brake caliper. Tighten the brake hose bolt to 44 Nm (32 ft. lbs.). 3. Remove the plug or cap from the exposed brake pipe fitting. 4. Install the brake hose to the brake pipe. Important: Ensure that the brake hose is not twisted and does not come in contact with any of the suspension components. 5. Using a backup wrench on the brake pipe fitting, tighten the brake hose fitting. Tighten the brake hose fitting to 17 Nm (13 ft. lbs.). 6. Install the brake pipe retaining clips. 7. Bleed the hydraulic brake system. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Refer to Vehicle Lifting. Page 1240 Application Table Part 2 Page 8346 WA8554/40 - WA8555/41 Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure Caution: Refer to Protective Goggles and Gloves Caution in Service Precautions. Notice: Refer to General Vehicle Lifting and Jacking Notice in Service Precautions. 1. Raise and suitable support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust manifold pipe to manifold flange bolts. 3. Remove the exhaust manifold pipe from the exhaust manifold 4. Remove and discard the seal. Installation Procedure 1. Install the exhaust manifold pipe and NEW seal to the exhaust manifold. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust manifold pipe to manifold flange bolts. ^ Tighten the exhaust manifold pipe to manifold flange bolts to 30 Nm (22 ft. lbs.). 3. Lower the vehicle, Page 3320 Tighten the distributor clamp bolt to 25 N.m (18 lb ft). 8. Install the distributor cap. 9. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. 13. Repeat installation procedure 2 if the malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the MIL is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. Page 257 Seat Adjuster Switch - Driver (w/ 6-Way) Part 2 Page 1908 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite the rotor segment when the driven gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. Page 9084 Page 353 1. Install sensor into the hub and bearing assembly (6). Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. 8. Lower the vehicle. Refer to Vehicle Lifting. Specifications Tie Rod: Specifications Inner Tie Rod to Relay Rod Nut 35 ft. lbs. Outer Tie Rod to Steering Knuckle Nut 39 ft. lbs. Tie Rod Adjuster Sleeve Nuts 16 ft. lbs. Tie Rod to Steering Knuckle Nut 39 ft. lbs. Page 1478 sprocket. 7.3. Remove the bolt that was installed in the end of the crankshaft. 7.4. Install the engine front cover. Page 455 Floor Pedals Page 5508 Equivalent - Decimal And Metric Part 1 Page 5716 C106 (Forward Lamp Harness To Body Harness) Part 2 C106 (Forward Lamp Harness To Body Harness) (Export) Page 163 Body Control Module (BCM) C3 Part 2 Page 787 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 9834 Abbreviations And Meanings - Part 20 Page 8202 4. Remove the 2 short screws (1, 2) from the sunroof panel window garnish molding. 5. Remove the 8 screw covers (3) from the lower sunroof panel window garnish molding. 6. Remove the 8 garnish molding screws. 7. Remove the sunroof panel window garnish molding from the vehicle. Installation Procedure 1. Position the garnish molding to the headliner. 2. Ensure the sunroof switch wiring is positioned properly through the garnish molding. Page 7381 Page 2230 Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 9248 Page 8919 5. Connect the cruise control cable locator clip to the rectangular hole in the routing bracket. 5.1. Route the cruise control cable above the accelerator cable. 5.2. Ensure that the clip snaps securely into place. 6. Connect the electrical connection to the cruise control servo module. 7. Test the systems operation. 8. Perform the Cruise Control System Functional Test. 9. Close hood. Service and Repair Tailgate Interior Trim Panel: Service and Repair End Gate Cover Replacement Removal Procedure 1. Remove the handle from the handle assembly. Remove the endgate trim panel. 2. Remove the endgate bellcrank rod from the endgate inside handle assembly. 3. Remove the screws that retain the endgate cover to the endgate. 4. Remove the endgate cover from the endgate. 5. Release the endgate latch rods from the latch rod clips. 6. Drill out the rivets that secure the handle assembly to the endgate. 7. Remove the handle from the endgate cover. Installation Procedure 1. Install the inside handle assembly to the endgate cover using 2 rivets. Specifications Fuel Gauge Sender: Specifications Page 239 Power Door Lock Switch: Service and Repair POWER ACCESSORY SWITCH PANEL REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the power accessory switch panel from the armrest. Use a flat-bladed tool in order to carefully pry the cover up at the front leading edge. 3. Disconnect the electrical connectors from the switch. 4. Remove the switches from the switch mounting panel, if necessary. INSTALLATION PROCEDURE 1. Install the switches to the switch mounting panel, if necessary. 2. Connect the electrical connectors to the switch. 3. Install the power accessory switch mounting panel to the armrest. Ensure that the retainers lock into place. 4. Connect the battery negative cable. Page 9687 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 9527 Abbreviations And Meanings - Part 23 Page 5139 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 2250 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Service and Repair Headliner: Service and Repair Headliner Replacement (Utility) Removal Procedure 1. Remove the sunroof console, if equipped. 2. Remove the dome lamp. 3. Remove the sunroof opening trim, if equipped, by grasping it at the edge and pulling it away from the headliner. 4. Remove the coat hooks. 5. Remove the assist handles. 6. Remove the sunshades and the retainers. 7. Remove the windshield garnish moldings. 8. Remove the body lock pillar trim panels (4-door models only). 9. Remove the upper seat belt anchor bolts (2-door models only). 10. Remove the inside air temperature sensor grille. 11. Remove the body side trim panel. 12. Remove the rear upper garnish molding. 13. Remove the headliner from the vehicle. Installation Procedure Page 1044 Heater Hose: Service and Repair Heater Hose - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Release the outlet heater hose clamp using the J 38185 at the heater core. 3. Remove the outlet heater hose from the heater core. 4. Release the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Remove the heater inlet hose from the intake manifold fitting. 6. Release the heater outlet hose clamp using the J 38185 at the water pump. 7. Remove the heater outlet hose from the water pump. Page 8229 Door Lock Cylinder Switch - Front Passenger Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 4727 5. Install the park brake cable, on the equalizer 6. Install the park brake cable in the connector. 7. Adjust the park brake. 8. Lower the vehicle. Refer to Vehicle Lifting. Page 5310 C119 (4WAL/SIR Harness To AIR Jumper Harness) Page 6527 Registered And Non-Registered Trademarks - Part 1 Diagrams Idle Air Control (IAC) Valve Page 9530 Abbreviations And Meanings - Part 26 Page 5085 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 824 Power Window Switch: Connector Views Door Lock And Window Switch - Driver C1 Part 1 Service and Repair Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. - Tighten the backup lamp switch to 37 Nm (27 ft. lbs.). 2. Connect the backup lamp switch electrical connector. 3. Lower the vehicle. Page 5087 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 6714 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ......................................................................................................................................... Polyalkaline Glycol (PAG) Refrigerant Oil Page 2820 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate window latch support. 2. Disconnect the electrical connectors, as needed. 3. Remove the clip that retains the liftgate lock cylinder to the liftgate. 4. Remove the liftgate lock cylinder from the liftgate. Installation Procedure 1. Install the liftgate lock cylinder to the liftgate. 2. Install the clip that retains the liftgate lock cylinder to the liftgate. 3. Connect the electrical connectors, as needed. 4. Install the liftgate window latch support. Locations Sunroof Components (ZRX, Extreme W/ CF5) Page 8373 WA5322/33 - WA534F/54 Page 1741 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2 - 3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: ^ Engine oil diluted by moisture or unburned fuel mixtures ^ Improper engine oil viscosity for the expected temperature ^ Incorrect or faulty oil pressure gage sensor ^ Incorrect or faulty oil pressure gage ^ Plugged oil filter ^ Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6 psig) minimum, at 1,000 RPM 7.2. 125 kPa (18 psig) minimum, at 2,000 RPM 7.3. 166 kPa (24 psig) minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: ^ Oil pump worn or dirty ^ Malfunctioning oil pump pressure relief valve ^ Oil pump screen loose, plugged, or damaged ^ Excessive bearing clearance ^ Cracked, porous or restricted oil galleries ^ Engine block oil gallery plugs missing or incorrectly installed ^ Broken valve lifters Page 1197 Application Table Part 4 Procedures Rear Fender Liner: Procedures SIGHT SHIELD REPLACEMENT - REAR WHEELHOUSE PANEL REMOVAL PROCEDURE 1. Remove the push-pins retaining the sight shield to the vehicle frame. 2. Remove the sight shield. INSTALLATION PROCEDURE 1. Position the sight shield on the vehicle frame. 2. Install the push-pin retainers through the sight shield into the frame. Page 8156 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: Page 8536 Memory Seat Module - Driver C1 Part 3 Memory Seat Module - Driver C2 Part 1 Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 5943 Pitman Arm: Service and Repair Pitman Arm Replacement ^ Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29107-A Pitman Arm Puller - J 6632-01 Pitman Arm Remover - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Important: Use the proper tool in order to remove the relay ball stud nut. 2. Remove the relay rod ball stud at the pitman arm. 3. Remove the relay rod ball stud from the pitman arm using J 24319-B. Notice: Do not hammer on the pitman arm, pitman arm shaft or puller. Damage to the pitman arm or steering gear may result. 4. Remove the pitman arm nut and washer from the steering gear. Page 2453 9. Remove the CMP sensor. 10. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 11. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Drive out the roll pin with a suitable punch. 13. Remove the driven gear from the distributor shaft. Page 6911 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Page 6180 8. Remove the bolts and the balance shaft retainer. Important: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft. 9. Use a soft-faced hammer in order to remove the balance shaft from the engine block. 10. Clean and inspect the balance shaft. Installation Procedure Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft. 1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent to the balance shaft front bearing. 2. Use the J 36996 and the J 8092 in order to install the balance shaft. Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR ASSEMBLY Fuel Pressure Regulator Assembly The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. The fuel pressure regulator compensates for engine load by increasing fuel pressure as the engine vacuum drops. Page 6198 Tighten the shock absorber upper nut to 12 Nm (106 inch lbs.), while holding the stem with a wrench. 6. Install new nuts, if needed. 7. Install the shock absorber lower bolts through the pivot holes to the lower control arm holes. Tighten the shock absorber lower bolts to 30 Nm (22 ft. lbs.). 8. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: ^ Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force, which may result in personal injury. ^ To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Locations Shift Solenoid: Locations Steering Column Components Page 8606 1. Install the rear seatback filler panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear seatback filler panel retaining nuts. Tighten the rear seatback filler panel retaining nuts to 80 N.m (59 lb ft). Page 1946 Coolant: Fluid Type Specifications Engine Coolant 50/50 mixture of clean, drinkable water and use only GM Goodwrench DEX-COOL or Havoline DEX-COOL Coolant. Page 181 Powertrain Control Module (PCM) Connector C2 Part 3 Page 745 Page 9018 Registered And Non-Registered Trademarks - Part 3 Page 7872 Rear Door Panel: Service and Repair Door Inner Panel Replacement - Rear Side Door Inner Panel Replacement - Rear Side Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the screws that retain the front trim molding to the door. 2. Remove the trim molding from the door. 3. Use the J 38778 in order to remove the rear trim moldings. 4. Remove the retainers from the rear trim molding. Installation Procedure 1. Install the retainers to the rear trim molding. 2. Install the rear trim molding to the door. 3. Install the front trim molding to the door. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws that retain the front trim molding to the door. Tighten the screws to 1.9 N.m (17 lb in). Page 5361 C432 (Body Harness To Defogger Grid Harness) Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or contamination. Page 5583 Fuse Block - I/P Part 5 Fuse Block - Underhood Connector C1 Page 5370 C501 (Body Harness To LH Front Door Harness) (4-Door) Part 3 C601 (Body Harness To Door Harness, RH Front) (W/ Power Locks/Windows) Part 1 Page 2793 Powertrain Control Module (PCM) Connector C2 Part 3 Page 6295 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 8764 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. 2. Connect the electrical connector to the switch. 3. Install the trim panel to the seat with the 3 screws. 4. Install the seat to the vehicle. Page 3873 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) Page 4347 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 3452 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 1570 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve rocker arm assemblies as follows: 4.1. Finger start the bolt at location (1). 4.2. Finger start the bolt at location (2). 4.3. Finger start the bolt at location (3). 4.4. Finger start the remaining valve rocker arm bolts. 5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57 - 63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the valve rocker arm bolts Tighten valve rocker arm bolts to 30 Nm (22 ft. lbs.). 7. Install the valve rocker arm cover. Page 9476 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 2531 Engine Coolant Temperature (ECT) Sensor Page 6519 Abbreviations And Meanings - Part 20 Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 805 Abbreviations And Meanings - Part 14 Page 2166 Ignition Control Module (ICM) Diagrams Ambient Air Temperature Sensor (DIC) Page 9588 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 955 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 7248 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Service Precautions Hose/Line HVAC: Service Precautions CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED. MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. Page 3196 4. Install the air cleaner outlet duct retaining wingnut. Tighten Tighten the wingnut to 2 N.m (18 lb in). 5. Connect the breather tube to the air cleaner outlet duct. Page 4673 1. Install the metal gaskets (copper) on the brake hose bolt. Notice: Refer to Fastener Notice in Service Precautions. Important: The brake hose must not be twisted. Ensure that the brake hose is not in contact with any of the suspension components. 2. Install the front brake hose to brake caliper. Tighten the front brake hose bolt to 54 Nm (40 ft. lbs.). 3. Remove the rubber cap or plug from the brake pipe fitting. 4. Install the brake hose to the brake pipe. 5. Using a backup wrench, tighten the brake hose and the brake pipe fitting. Tighten brake hose fitting to 17 Nm (13 ft. lbs.). 6. Install the brake hose retaining bracket to the upper control arm. 7. Install the brake hose retaining bracket bolt and nut. Tighten brake hose retaining bracket nut to 22 Nm (16 ft. lbs.). 8. Install the brake hose retaining clip at the frame. 9. Bleed the hydraulic system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Page 161 Body Control Module (BCM) C2 Part 3 Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 5120 Abbreviations And Meanings - Part 13 Service and Repair License Plate Bracket: Service and Repair License Bracket Replacement - Front Removal Procedure 1. Remove the grille. 2. Drill out the rivets that retain the bracket to the front air deflector. 3. Remove the bracket from the front air deflector. Installation Procedure 1. Drill 4 new holes in the air deflector using a drill jig if a new air deflector has been installed. 2. Install the bracket to the front air deflector with 4 rivets. 3. Install the grille. Page 9358 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 8364 WA160E/06 - WA228A/55 Page 9238 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting bolt. Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). Page 9419 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 565 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Locations Seat Belt Components Page 5907 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Important: Before you adjust caster and camber angles, raise and release the front bumper. Do this twice in order to allow the vehicle to return to a normal height. 1. Adjust the caster and the camber by inserting shims between the upper control arm shaft and the frame bracket. Add shims or subtract shims or transfer shims in order to change the readings. 2. In order to adjust the caster and the camber, loosen the upper control arm shaft-to-frame nuts (1). Add shims or remove shims (2) as required. Tighten the nuts. Check the toe after you change the caster and the camber. 3. Caster-Transfer the shims from front to rear or from rear to front. The transfer of one shim from the rear bolt to the front bolt decreases positive caster. 4. Camber-Change the shims at the front and the rear of the cross shaft. Add an equal number of shims at the front and the rear of the cross shaft. This decreases positive camber. 5. A normal shim pack will leave at least two threads of the bolt exposed beyond the nut (1). The difference between the front shim pack and the rear shim pack must not exceed 10 mm (0.40 inch). If you cannot meet these requirements, check for damage to the control arms and to related parts. 6. Tighten the nut on the thinner shim pack first. This improves the shaft-to-frame clamping force. This also improves torque retention. Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 1221 Fuse Block - Underhood Connector C2 Part 4 Page 7241 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 7434 A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 9397 Abbreviations And Meanings - Part 10 Page 8517 8. Install the sunroof panel window garnish molding (3). 9. Install the 15A fuse to the jumper harness as removed. Page 5153 Application Table Part 3 Page 2533 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Page 2401 Steps 13-14 Page 4756 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting bolt. Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Specifications Oil Level Sensor: Specifications Engine Oil Level Sensor ...................................................................................................................... ................................................ 13 Nm (115 inch lbs.) Page 3166 7. Disconnect the lower fuel fill tube (12) from the upper fuel fill hose (11). 8. Remove the fuel fill tube (12). INSTALLATION PROCEDURE 1. Position the fuel fill tube (12) over the frame crossover. 2. Connect both the upper (11) and lower (13) fuel fill hoses to the lower fuel fill tube (12). 3. Install the lower fuel fill tube retaining bolt to the frame crossover. NOTE: Refer to Fastener Notice in Service Precautions. Page 1109 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Page 5282 C310 (Sunroof Jumper Harness To Sunroof Harness) (ZRX/Extreme With RPO Code CF5) Page 9161 Driver Information System Diagram 3 Page 9216 Disclaimer Latch Control Handle Replacement - Side Rear Door Rear Door Interior Handle: Service and Repair Latch Control Handle Replacement - Side Rear Door LATCH CONTROL HANDLE REPLACEMENT - SIDE REAR DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Release both lock rods from the lock rod retainers (1) on the handle. 3. Remove the bolts retaining the latch control handle to the door. 4. Remove the latch control handle from the door. INSTALLATION PROCEDURE 1. Install the latch control handle to the door. 2. Install the bolts retaining the latch control handle to the door. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 8 N.m (71 lb in). 3. Position the upper lock rod in the retainer (1) so that there is 10 1-2 mm (0.39-0.47 in). (Approximately 11-12 threads showing) from the end of the lock rod. 4. Position the lower latch rod in the retainer where it rests, usually 5-6 mm (0.19-0.23 in) of threads showing from the end of the latch rod. 5. Check for proper door operation. 6. Install the door trim panel. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 7147 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION The driver information center (DIC) consists of a multi-function electronic display placed in the overhead console. The DIC displays the following information: - The vehicle fuel information - The outside temperature - The direction the vehicle is facing The display parameters are cycled, changed, and acknowledged using the following 2 DIC buttons mounted at the side of the driver information center: US/MET: Allows the display to switch between English and Metric units. MODE: Used to toggle between OFF, COMP/TEMP and TRIP. COMP/TEMP COMP: In the Compass Mode, one of eight compass readings (N, NE, E, SE, S, SW, W, and NW) will be displayed to indicate the direction the vehicle is facing. TEMP: In the Temperature Mode, the outside air temperature is displayed in either °C or °F. If the outside air temperature is below 3°C (37°F), the display will toggle between ICE and the current outside air temperature in 8 second increments. TRIP: In the Trip Mode, the DIC displays the following information based on class 2 serial data: AVG ECON: The DIC displays the average fuel economy since the last reset. AVG SPEED: The DIC displays the average speed since the last reset. FUEL USED: The DIC displays the amount of fuel used since the last reset. INST ECON: The DIC displays the instantaneous fuel economy since the last second of driving. RANGE: The DIC displays the estimated distance that can be travelled with the remaining fuel in the tank, based on the fuel economy for the last few hours of driving. The display format for each mode is indicated in the table. Page 8171 Scuff Plate: Service and Repair Door Sill Plate Replacement - Lift Gate Door Sill Plate Replacement - Lift Gate Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Use the J 38778 in order to remove the door sill trim plate from the vehicle. Installation Procedure Install the door sill trim plate to the vehicle. Align the retainers along the door sill and press into place. Page 5891 Frame Angle Measurement (Express / Savana Only) ........ Page 7886 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Open the rear side door window. 2. Remove the rear side door window weatherstrip. Start the at butt joint and pull the weatherstrip from the window opening. Installation Procedure 1. Install the rear side door weatherstrip. 2. Locate the butt joint at the bottom center of the window opening and set the weatherstrip around the window opening. Page 9603 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 9768 Page 1161 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Compressor Oil Balancing See: Heating and Air Conditioning/Service and Repair/Flushing Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. See: Specifications/Capacity Specifications Page 4321 3.2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. 6. Enable the SIR system. Page 9536 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 1600 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use J 38606 when J 5892-D will not fit. 11. Remove the valve keys (1) 12. Carefully release the valve spring tension 13. Remove the J 5892-D or the J 38606. 14. Remove the valve spring cap (2) and valve spring (3). 15. Remove the valve stem oil seal (4). Installation Procedure Page 3986 1. Install the transmission mount to the vehicle. Notice: Refer to Fastener Notice Service Precautions. 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ For vehicles equipped with 2.2L, tighten tine bolts to 45 Nm (33 ft. lbs.). ^ For vehicles equipped with 4.3L, tighten the bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 57 Nm (42 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Page 3242 Camshaft Position (CMP) Sensor Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Handle Replacement - Front Inside Door Handle Replacement - Front Inside Removal Procedure 1. Remove the door trim panel. 2. Remove the inside door handle rods. 3. Remove the inside door handle retaining rivets. 4. Remove the inside door handle from the door by sliding the handle rearward. Installation Procedure 1. Install the inside door handle to the door by sliding the handle forward. Ensure that the handle is properly seated. 2. Install the inside door handle retaining rivets. 3. Install the inside door handle rods. 4. Install the door trim panel. Door Handle Replacement - Inside Door Handle Replacement - Inside Removal Procedure 1. Remove the door trim panel. Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Service and Repair Camshaft Gear/Sprocket: Service and Repair Timing Chain and Sprockets Replacement ^ Tools Required J 5825-A Crankshaft Gear Remover - J 5590 Crankshaft Gear Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both Sprockets line up. 4.2. The number four cylinder is at Top Dead Center (TDC) of the compression stroke. Page 8693 Abbreviations And Meanings - Part 13 Page 6103 Abbreviations And Meanings - Part 26 Page 7225 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5201 Application Table Part 3 Page 8658 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 2682 Abbreviations And Meanings - Part 2 Testing and Inspection Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids Inspect the connectors at the BCM, and all other circuit connecting points for an intermittent condition. Inspect the circuit wiring for an intermittent condition. If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Page 8605 4. Install the cable (3) to the seat back pivot assembly. 5. Install the cable (3) to the pivot assembly bracket by tightening cable nut (2). 6. Install the cable cover bracket (2) to the seat back pivot assembly. 7. Install the 2 bolts (1). Tighten the bolts to 24 N.m (18 lb ft) 8. Pull the pad and cover back over the seat frame. 9. Install the pad and cover to seat with J-strips (1). 10. Install the spring (2) to the seat adjuster rail. 11. Install the seat back recliner handle. 12. Install seat in the vehicle. Seat Back Filler Panel Replacement - Rear Seat Back Filler Panel Replacement - Rear Removal Procedure 1. Fold down the rear seat to access the rear seatback filler panel retaining nuts. 2. Remove the rear seatback filler panel retaining nuts. 3. Remove the rear seatback filler panel. Installation Procedure Page 2850 OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 7133 Abbreviations And Meanings - Part 26 Page 1108 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Page 2690 Abbreviations And Meanings - Part 10 Page 4924 Abbreviations And Meanings - Part 24 Page 9697 Equivalent - Decimal And Metric Part 1 Page 9831 Abbreviations And Meanings - Part 17 Page 5089 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 6520 Abbreviations And Meanings - Part 21 Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 1 Page 9912 2. Install the window regulator handle to the door. 3. Install the retaining clip to the handle. 4. Insert the handle onto the window regulator shaft. Ensure that the handle points toward the front of the door. 5. Push on the handle until the clip engages on the shaft. Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Page 1230 Fuse Block - Underhood Connector C6 Relay Block - Body Page 7239 Page 6147 Control Arm Bushing: Service and Repair Lower Control Arm Bushings Replacement Lower Control Arm Bushings Replacement ^ Tools Required J 21474-01 Control Arm Bushing Service Set - J 22269-01 Accumulator and Servo Piston Remover Removal Procedure 1. Remove the lower control arm from the vehicle. 2. Install the lower control arm in a vise. 3. Remove the rear bushing. 3.1. Install the following tools: ^ The J 22269-01 ^ The J 21474-8 ^ The J 21474-12 ^ The J 21474-13 3.2. Tighten until the rear bushing becomes free. 4. Using a blunt chisel, drive the front bushing flare down flush with the rubber part of the bushing. 5. Prior to removing or installing the front bushing, place a wedge or spacer between the control arm bushing housing. This keeps the control arm bushing housing from bending while removing or installing the bushing. 6. Remove the front bushing. 6.1. Install the following tools: ^ The J 21474-3 ^ The J 21474-4 ^ The J 21474-5 ^ The J 21474-6 6.2. Tighten until the bushing is partially removed. Page 6090 Abbreviations And Meanings - Part 13 Page 5706 C430 (Chassis Harness To License Lamp Harness) (Domestic) Page 709 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 8242 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left side instrument panel sound insulator. 2. Disconnect the electrical connector. 3. Remove the remote control door lock receiver from the instrument panel sound insulator by unsnapping it. INSTALLATION PROCEDURE 1. Install the remote control door lock receiver from the instrument panel sound insulator by snapping it. 2. Connect the electrical connector. 3. Install the left side instrument panel sound insulator. 4. Reprogram the transmitters. See: Testing and Inspection/Programming and Relearning 5. Test the operation of the system. Page 3413 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 1942 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 944 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at top dead center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1) or V8 engine (2). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when the gear is installed in the distributor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. Page 8389 WA8555/41 - WA8555/41 Page 412 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting bolt. Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). Page 8940 Page 1388 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 1176 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Page 6443 2. Install the screw (1) securing the air outlet assembly to the instrument panel carrier. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the air outlet assembly screw to 1.9 N.m (17 lb in). 3. Install the air distribution duct. 4. Install the Instrument panel carrier. Page 8208 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the upper (3) and lower (7) seat belt anchor bolts. Tighten the seat belt anchor bolts to 70 N.m (52 lb ft). 6. Install the door sill trim plate. Trim Panel Replacement - Body Side (2-Door Utility) Trim Panel Replacement - Body Side (2-Door Utility) Removal Procedure Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Window Removal Procedure In order to remove the liftgate window weatherstrip from the pinch-weld flange, perform the following steps: 1. Open the liftgate window. 2. Firmly grip the weatherstrip. 3. Pull the weatherstrip. Installation Procedure 1. Open the liftgate window. 2. Push the weatherstrip onto the pinch-weld flange. Begin with the pre-formed corner at either upper corner of the liftgate window opening. 3. Completely seat the weather-strip around the liftgate window opening. Page 6411 1. Start the new stud into the axle flange hole by pressing firmly with your hand. 2. Install a washer and thread the lug nut on the wheel stud with the flat side of the lug nut to the vehicle. 3. Tighten the lug nut in order to draw the wheel stud into the rear of the flange. 4. Remove the lug nut and washers from the wheel stud. 5. Install the brake drum. 6. Install the tire and the wheel. 7. Lower the vehicle. (Rear Disc Brakes) Wheel Stud Replacement (Rear Disc Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Page 3619 Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. Important: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. 6.1. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. 6.2. Remove the 1-2 accumulator inner and outer springs. 7. Inspect the 1-2 accumulator inner and outer springs for cracks. Page 4054 Valve Body Spring and Bore Plug Chart (inch) Page 1217 Fuse Block - Underhood Connector C1 Part 8 A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 751 Page 9971 2. Install the retaining nut onto the wiper transmission drive shaft and the wiper arm. Tighten Tighten the nut to 23 N.m (17 lb ft). 3. Install the cover on the wiper arm nut. Page 8844 Truck Bed: Service and Repair Pickup Box Replacement Pickup Box Replacement Removal Procedure 1. Lower the spare tire. 2. Remove the rear tail lamp assemblies. 3. Remove the bolts that retain the frame to the pickup box. 4. Remove the wiring harness ground wire from the frame. 5. Remove the license plate lamp. 6. Remove the ground wire that retains the fuel filler neck to the pickup box. 7. Remove the screws that retain the fuel filler neck to the pickup box. 8. With an assistant, remove the pickup box from the vehicle. Installation Procedure 1. With an assistant, install the pickup box to the vehicle. 2. Install the screws that retain the fuel filler neck to the pickup box. 3. Install the ground wire that retains the fuel filler neck to the pickup box. 4. Install the license plate lamp. 5. Install the wiring harness ground wire to the frame. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that retain the frame to the pickup box. Tighten the bolts to 70 N.m (52 lb ft). 7. Install the rear tail lamp assemblies. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 4912 Abbreviations And Meanings - Part 12 Page 9020 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 4320 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SM Caution In Service Precautions. 1. Disable the SIR system. 2. Remove the steering column trim covers. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. Oil Filter Adapter Replacement Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Oil Filter Adapter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the engine oil cooler pipe bolt from the oil filter adapter. 4. Remove the engine oil cooler adapter pipes and seals from the oil filter adapter. 5. Remove the engine oil filter (except Four Wheel Drive vehicle). 6. Remove oil filter adapter bolts. 7. Remove the oil filter adapter and the oil filter adapter gasket. Page 5684 C224 (Body Harness To Ashtray Insert) Page 4656 1. Install the caliper bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear brake caliper bracket mounting bolts. Tighten the rear brake caliper bracket mounting bolts to 70 Nm (52 ft. lbs.). 3. Install the rear brake anti rattle retainers. 4. Install the rear brake pads. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Refer to Vehicle Lifting. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the brake master cylinder to the proper level. Page 3752 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Diagrams Tow/Haul Switch Page 1879 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 6971 1. Install the radio antenna cable. 2. Install the radio antenna cable screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the radio antenna cable screws to 2.8 N.m (25 lb in). 3. Install the radio antenna bezel. 4. Install the radio antenna cable nut. 5. Install the fender. Tighten Tighten the radio antenna cable nut to 6 N.m (53 lb in). 6. Install the radio antenna cable to the radio extension cable. 7. Install the antenna mast. Page 6302 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 8600 4. Disconnect the electrical connector for the seat back recliner motor, if equipped. 5. Remove the bolts securing the seat back to the seat adjuster assembly. 6. Remove the seat back. Installation Procedure 1. Install the seat back to the seat adjuster assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts securing the seat back to the seat adjuster assembly. Tighten the seat back bolts to 24 N.m (18 lb ft). 3. Connect the electrical connector for the seat back recliner motor, if equipped. 4. Install the seat cushion trim cover and pad. 5. Install the seat back cover and pad. 6. Install the seat in the vehicle. Seat Back Cover and Pad Replacement - Front Seat Back Cover and Pad Replacement - Front Removal Procedure 1. Remove the head restraint, if equipped, from the seat back. 2. Remove the EZ entry release handle, if equipped, from the seat back. 3. Separate the J-strip at the base of the seat back. 4. Remove the seat cover from the pad by sliding the cover upward off the seat back. Page 6349 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 4480 Page 3798 Disclaimer Page 5074 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 7021 For vehicles repaired under warranty use, the table. Disclaimer Page 5661 C203 (Body Harness To IP Harness) Part 2 Page 4384 Page 1871 Disclaimer Page 9792 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 3183 Steps 1-2 Page 7272 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6039 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1203 Location View Page 2677 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 8573 Seat Adjuster Switch - Driver/Front Passenger (w/ Memory) Part 1 Page 9817 Abbreviations And Meanings - Part 3 Page 2052 12. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 3640 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Remove the rear bumper impact bar. 2. Remove 4 nuts and 2 stud plate assemblies securing the trailer hitch to each frame rail. 3. Remove the hitch from the frame rails. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the trailer hitch to each frame rail with 4 nuts and 2 stud plate assemblies. Tighten the trailer hitch nuts to 90 N.m (66 lb ft). 2. Install the rear bumper impact bar. Service and Repair Antenna Mast: Service and Repair FIXED ANTENNA MAST REPLACEMENT REMOVAL PROCEDURE 1. Unscrew the antenna mast. NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 2. Remove the antenna mast from the antenna base. INSTALLATION PROCEDURE Page 1926 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 2413 Disclaimer Page 3838 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Connector Views Fuse Block: Connector Views Fuse Block - I/P Part 1 Removal Compressor Clutch Coil: Service and Repair Removal With RPO Code HT6/HD6/HU6 COMPRESSOR CLUTCH COIL REMOVAL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED - J 6083 External Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 8433-1 Puller Bar - J 33025 Clutch Coil Puller Legs - J 8433-3 Forcing Screw 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: - The pulley rotor (1) - The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. Page 7228 Page 1758 27. Connect the following electrical connectors: ^ The Idle Air Control (IAC) motor (3) ^ The Throttle Position (TP) sensor (2) ^ The A/C compressor cutoff switch, if equipped (5) ^ The A/C clutch switch, if equipped (1) ^ The Engine Coolant Temperature (ECT) sensor (4) 28. Connect the following electrical connectors: ^ The fuel meter body assembly (1) ^ The EVAP canister purge solenoid valve (2) ^ The Manifold Air Pressure (MAP) sensor (3) 29. Connect the following electrical connectors: ^ The ignition coil (2) Page 5170 Fuse Block - Underhood Connector C1 Part 1 Page 8848 3. Install the step pad to the step panel using the following steps: 3.1. Insert the locator pin on the pad into the hole in the panel. 3.2. Press the retainer tabs on the pad into the holes in the panel. 4. Install the forward brace to the forward support bracket using the 1 screw. Tighten Tighten the forward brace to forward support bracket screw to 9.0 N.m (6.6 lb ft). 5. Install the forward brace to the step panel using the 1 screw. Tighten Tighten the screw to 9.0 N.m (6.6 lb ft). 6. Install the rear brace to the rear bumper bracket and step panel using the 2 screws. Tighten Tighten the rear brace screws to 9.0 N.m (6.6 lb ft). Page 7800 3. Install the C-clips that retain the door hinge roller pins. 4. Install the door hinge spring using the J 36604. 5. Lubricate the hinge roller pins using multi-purpose lubricant Superlube (GM P/N 12346241) or equivalent. Page 5444 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 4264 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side Page 3319 4. Using a long screw driver, align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine. 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. - There may be a 6 cast into this pointer, indicating that the distributor is to be used on a 6 cylinder engine or an 8, indicating that the distributor is to be used on a 8 cylinder engine. - If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more. - If this is the case, repeat the procedure again in order to achieve proper alignment. 7. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 2455 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. Page 4527 Brake Pad: Service and Repair Brake Pads Replacement - Rear Brake Pads Replacement - Rear Removal Procedure 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full and the minimum allowable level, using the appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. Page 6607 HVAC Control Assembly C5 Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 5797 Splice Pack SP204 Part 1 Page 5857 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 4717 4. Install the park brake equalizer. 5. Adjust the park brake. 6. Lower the vehicle. Refer to Vehicle Lifting. Page 3564 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 7258 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 9586 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement Removal Procedure 1. Remove the lower bumper valance. 2. Remove the bolts from the tow hooks. 3. Remove the hooks from the frame. Installation Procedure 1. Install the tow hooks to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the tow hooks. Tighten the bolts to 55 N.m (41 lb ft). 3. Install the lower bumper valance. Page 5335 C219 (Left Inflatable Restraint Discriminating Sensor Jumper Harness to the Right Sensor Harness) (With RPO Code K18) Page 4351 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Page 8259 Power Door Lock Actuator: Diagrams Door Lock Actuator - Driver Page 3338 Ignition Control Module: Description and Operation IGNITION COIL AND ICM The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Page 6146 1. Install the upper control arm shaft to the upper control arm. 2. Install the control arm bushings to the upper control arm. Use the J 22269-01 and a short piece of pipe that is the same outer diameter as the rubber bushing. 3. Tighten J 22269-01 until the bushing is positioned on the shaft and the upper control arm as shown. The measurement should be 12.8 - 13.8 mm (0.48 - 0.52 inch) on both ends. 4. Install the washers and the nuts to the upper control arm shaft. Do not tighten the nuts. 5. Remove the upper control arm from the vise. 6. Install the upper control arm to the vehicle. A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 6761 2. Install the vacuum hose(s). 3. Install the brake pressure modulator valve. Page 9668 Page 2683 Abbreviations And Meanings - Part 3 Page 4601 7. Adjust the rear brakes. 8. Install the tire and wheel. 9. Lower the vehicle. Refer to Vehicle Lifting. Page 4908 Abbreviations And Meanings - Part 8 Page 5825 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 8037 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Body Side - Lower Front (Chevrolet) Molding Replacement - Rear Body Side - Lower Front (Chevrolet) Tools Required J 25070Heat Gun Removal Procedure 1. Heat the body side molding using a J 25070. Hold the heat gun approximately 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or chip the paint. 2. Peel the body side molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel and the back of the body side molding using a 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 4. Clean the body panel using Varnish Makers and Painters (VMP) naphtha. Installation Procedure 1. Warm body panel with a heat lamp or heat gun to a minimum of 21°C (70°F). 2. Peel the backing from the front end of the body side molding. Important: Do not touch the adhesive backing. 3. Press the body side molding to the body while continuing to remove the backing. 4. Hand roll the body side molding to the body in order to ensure proper adhesion. Page 7267 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Description and Operation Torsion Bar: Description and Operation General Description (Torsion Bar) The front suspension has 2 primary purposes: ^ Isolate the driver from irregularities in the road surface. ^ Define the ride and handling characteristics of the vehicle. The front suspension absorbs the impact of the tires travailing over irregular road surfaces and dissipates this energy throughout the suspension system. This process isolates the vehicle occupants from the road surface. The rate at which the suspension dissipates the energy and the amount of energy that is absorbed is how the suspension defines the vehicle's ride characteristics. Ride characteristics are designed into the suspension system and are not adjustable. The ride characteristics are mentioned in this description in order to aid in the understanding of the functions of the suspension system. The suspension system must allow for the vertical movement of the tire and wheel assembly as the vehicle travels over irregular road surfaces while maintaining the tire's horizontal relationship to the road. This requires that the steering knuckle be suspended between an upper and a lower control arm. The lower control arm attaches from the steering knuckle at the outermost point of the control arm. The attachment is through a ball and socket type joint. The innermost end of the control arm is attached at 2 points to the vehicle frame through semi-rigid bushings. The upper control arm attaches to the frame in the same fashion. Attached to the lower control arm is a torsion bar. Torsion bars are steel or steel composite shaft that connects from the lower control arm an adjustable mount at the torsion bar crossmember. The torsion bar functions as a spring in this suspension system. The torsion bar absorbs energy from irregular road surfaces by twisting force along the center axis. The torsion bar has a resistance to this twisting motion and will return to the original, at-rest position similar to that of a spring. A shock absorber is used in conjunction with this system in order to dampen out the oscillations of the torsion bar. A shock absorber is a basic hydraulic cylinder. The shock is filled with oil and has a moveable shaft that connects to a piston inside the shock absorber. Valves inside the shock absorber offer resistance to oil flow and consequently offer resistance to rapid movement of the piston and shaft. Each end of the shock absorber is connected in such a fashion in order to utilize this recoil action of a torsion bar alone. Front suspension systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right lower control arm assemblies through the stabilizer link and stabilizer shaft insulators. This bar controls the amount of independent movement of the suspension when the vehicle turns. Limiting the independent movement defines the vehicle's handling characteristics on turns. Procedures Door Lock Cylinder: Procedures Binding Lock Cylinders BINDING LOCK CYLINDERS Correct binding or sticking door lock cylinders or keys that are hard to insert by applying the proper lubrication. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. DO NOT use penetrating lubricants (such as GM P/N 1052949 and WD-40(R)). These lubricants wash out the original lubrication and eventually evaporate, leaving little or no lubricating material. 1. Hold the lock cylinder shutter open using a paper clip or the equivalent. IMPORTANT: Do not damage the painted surfaces. 2. Force air into the cylinder using compressed air and a blow gun attachment. 3. While you hold the lock cylinder shutter open, inject a small amount of lubricant into the cylinder. 4. Work the key into the lock cylinder several times. 5. Wipe away any excess lubricant from the key. Lock Cylinder Replacement - Door LOCK CYLINDER REPLACEMENT - DOOR REMOVAL PROCEDURE New lock cylinders are available as replacement components. When you replace a lock cylinder, apply a coating of appropriate lubricant inside the lock case and the cylinder keyway prior to installing the cylinder. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. In order to repair a binding lock cylinder, refer to Binding Lock Cylinders . In order to code a new lock cylinder, refer to Key and Lock Cylinder Coding in General Information. 1. Remove the outside door handle. 2. Use a flat-bladed tool in order to remove the door lock cylinder retainer. 3. Remove the door lock cylinder from the outside door handle. INSTALLATION PROCEDURE Page 7689 Abbreviations And Meanings - Part 17 Specifications Rocker Arm Assembly: Specifications Valve Rocker Arm Bolt ........................................................................................................................ .................................................... 30 Nm (22 ft. lbs.) Valve Rocker Arm Cover Bolt ............................................................................................................................................................ 12 Nm (106 inch lbs.) Rocker Arms - Valve Rocker Arm Ratio ........................................................... ............................................................................................................ 1.5:1 Page 5588 Fuse Block - Underhood Connector C1 Part 5 Page 7309 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER DESCRIPTION AND OPERATION The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(tm) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer toGarage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the body control module (BCM). Page 8345 WA8554/40 - WA8554/40 Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 2183 Camshaft Position (CMP) Sensor Page 9789 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Locations Steering Column Components Page 6476 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 2369 Engine Generator And Starter Page 6481 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9606 Equivalent - Decimal And Metric Part 1 Page 789 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 7636 Page 4625 16. Discard the rubber O-rings. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent. 2. Dry the brake caliper pin bolts using non-lubricated, compressed filter air. 3. Lubricate the sleeves and bushings with Delco Silicone Lube, GM P/N 18010909, or equivalent. 4. Install the rubber O-ring bushings to the brake caliper. 5. Install the brake caliper mounting bolt sleeves. 6. Install the brake pads to the brake caliper. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the brake caliper mounting bolts. Tighten the brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Brake Hose Installation Notice in Service Precautions. Important: When performing the following service procedure, DO NOT reuse the washers, replace them with new washers. Page 1241 Application Table Part 3 Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint Lower Ball Joint Replacement ^ Tools Required J 23742 Ball Joint Separator - J 9519-D Ball Joint Remover and Installer Set Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Caution: Refer to Floor Jack Caution in Service Precautions. 3. Place a floor jack under the control arm spring seat. Raise the jack in order to support the control arm. Notice: Support the caliper with a piece of wire to prevent damage to the brake line. 4. Remove the brake caliper. 5. Remove the cotter pin and the nut. 6. Break the ball joint loose from the steering knuckle using the J 23742. Important: Place a wooden block between the frame and the upper control arm in order to lift the knuckle assembly out of the way. Page 8599 Seat Back: Removal and Replacement Seat Back Replacement - Front (Bench Seat) Seat Back Replacement - Front (Bench Seat) Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the recliner assembly. 3. Remove the seat back pivot bolt. 4. Remove the seat back from the lower frame. Installation Procedure 1. Install the seat back to the lower frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the seat back pivot bolt. Tighten the seat back pivot bolt to 47 N.m (35 lb ft). 3. Install the recliner assembly. 4. Install the seat to the vehicle. Seat Back Replacement - Front (Bucket Seat) Seat Back Replacement - Front (Bucket Seat) Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the seat back cover and pad. 3. Remove the seat cushion trim cover and pad. Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 5527 Abbreviations And Meanings - Part 6 Page 3399 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 4653 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front brake pads, outboard shown. 4. Remove the front brake caliper bracket mounting bolts, lower shown. 5. Remove the front brake caliper mounting bracket. Installation Procedure Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9515 Abbreviations And Meanings - Part 11 Page 1582 17. Inspect the valve rocker arm cover for the following: ^ Damage to the PCV valve grommet (1) ^ Damage to the bolt holes (2) A damaged valve rocker arm cover may interfere with the valve rocker arms. ^ Damage to the exterior of the valve rocker arm cover (3) ^ Gouges or damage to the sealing surface (4) ^ Damage to the oil fill tube grommet (5) ^ Restrictions to the ventilation system passages Installation Procedure Important: Do not reuse the valve cover gasket or the valve rocker arm cover bolt grommets. 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover. 2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover. Page 2010 Page 6871 6. Install the upper seat belt anchor plate and bolt to the vehicle. Tighten Tighten the upper seat belt anchor plate bolt to 70 N.m (52 lb ft). 7. Close the upper seat belt anchor plate cover. 8. Install the lower seat belt anchor plate and bolt to the vehicle. Tighten Tighten the lower seat belt anchor plate bolt to 70 N.m (52 lb ft). Page 4286 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 5258 C209 (Dome Harness To Body Harness) Part 1 Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision the front seat occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damage after a collision. Page 5067 Page 6578 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Mark the clutch coil terminal location (1) on the compressor front head. Refer to Clutch Rotor and/or Bearing Removal (HT6/HD6/HU6)Clutch Rotor and/or Bearing Removal (V7 - Direct Mount). 8. Install the J 33023-A on the front head of the compressor. 9. Install the J 8433-1 and the J 33025. 10. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2). V7 - Direct Mount COMPRESSOR CLUTCH COIL REMOVAL (V7 - DIRECT MOUNT) TOOLS REQUIRED - J 8433 Compressor Pulley Puller - J 8433-3 Forcing Screw - J 33023-A Puller Pilot - J 33025 Clutch Coil Puller Legs - J 41790 Compressor Holding Fixture Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9394 Abbreviations And Meanings - Part 7 Page 5525 Abbreviations And Meanings - Part 4 Page 1326 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Locations Electronic Components Page 5664 C203 (Body Harness To IP Harness) Part 5 Page 4723 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Rear (4WD Pickups and Utilities) Park Brake Cable Replacement - Rear (S4WD Pickups and Utilities) Removal Procedure Tools Required ^ J37043 Park Brake Cable Release Tool 1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the front cable at the equalizer. 4. Using the J37043 (1), collapse the locking finger for the rear park brake cable. 5. Remove the rear park brake cable from the connector. Page 2474 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 7177 Disclaimer OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 6047 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 9814 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 6502 Abbreviations And Meanings - Part 3 Page 7706 Steering Wheel Controls Switch - Right Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 983 Drive Belt Vibration Diagnosis Step 1 - 11 Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Page 2198 Engine, LR Locations Instrument Panel Details, RH Page 6494 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 8665 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Locations Locations View Driver Information Center Module Replacement Driver/Vehicle Information Display: Service and Repair Driver Information Center Module Replacement DRIVER INFORMATION CENTER MODULE REPLACEMENT REMOVAL PROCEDURE 1. Using a flat-bladed tool, carefully remove the display lens (1) from the overhead console (3). 2. Remove the electronic display module (2) from the console (3). 3. Disconnect the electrical connection. INSTALLATION PROCEDURE 1. Connect the electrical connection. 2. Install the electronic display module (2) to the overhead console (3). 3. Install the display lens (1) by snapping the lens into place. 4. Calibrate the compass. Page 9490 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 9127 Abbreviations And Meanings - Part 5 Page 4989 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4470 Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the steering column at the support bracket. 2. Remove the brake pedal pivot bolt and discard the bolt. 3. Remove the brake pedal. 4. Inspect the brake pedal pivot bushing for damage or wear. Installation Procedure 1. If the brake pedal pivot bushing is damaged or worn, replace the bushing using the following procedure: 1.1. Squeeze the end that will be facing the brake pedal pivot nut. 1.2. Insert the bushing into the pivot hub just enough to hold the bushing in place. 1.3. Rapidly push the bushing through the hub until the bushing snaps in place. 2. Install the brake pedal. Notice: Refer to Fastener Notice in Service Precautions. Important: The brake pedal pivot bolt is a prevailing torque bolt and must be replaced each time the bolt is removed. 3. Install the new brake pedal pivot bolt and the brake pedal pivot nut. Tighten the brake pedal pivot bolt to 25 Nm (19 ft. lbs.). 4. Install the steering column. Page 480 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 974 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Step 1 - 6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Page 4335 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 7099 Conversion English/Metric Part 2 Page 8708 Registered And Non-Registered Trademarks - Part 1 Page 638 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 286 Sunroof / Moonroof Switch: Diagrams Sunroof Motor (Sunroof Switch C1) Page 5668 C203 (Body Harness To IP Harness) Part 9 Page 4626 8. Install the front brake hose fitting, the 2 new gaskets and the brake hose fitting bolt. Tighten the front brake hose bolt to 54 Nm(40 ft. lbs.). 9. Fill the brake master cylinder to the proper level. 10. Bleed the brake caliper. 11. Inspect the brake system for leaks. 12. Install the tire and wheel assembly. 13. Lower the vehicle. Refer to Vehicle Lifting. Page 9775 Page 2464 Tighten the distributor clamp bolt to 25 N.m (18 lb ft). 8. Install the distributor cap. 9. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. 13. Repeat installation procedure 2 if the malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the MIL is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. Page 694 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 5003 Conversion English/Metric Part 2 Page 578 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 524 Engine, LR Page 5048 Tighten Tighten the differential carrier bolts to 25 N.m (18 lb ft). 6. Lower the vehicle. 7. Connect the battery negative cable. Page 9672 Page 3169 1. Install the fuel filler pipe. 2. Refill the fuel system. 3. Install the fuel filler cap. 4. Connect the negative battery cable. 5. Inspect for leaks. Page 7432 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 2713 Data Link Connector (DLC) Page 1455 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster (charged) battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster (charged) battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed (leave the hazard flashers ON). 2.5. Turn OFF the ignition switch. 3. Attach the end of 1 jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 4. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 5. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative booster cable to the housings of other vehicle electrical accessories or equipment. The current flow during jump starting may damage such equipment. 6. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1500 RPM. 7. Crank the engine of the vehicle with the battery. If the engine does not crank or cranks too slowly, perform the following steps: 7.1. Turn the ignition OFF. 7.2. Allow the booster vehicle engine to run at approximately 1500 RPM for 5 minutes. 7.3. Attempt to start the engine of the vehicle with the discharged battery. Page 3107 1. Lubricate the new injector O-ring seals with clean engine oil (2). 2. Install the O-rings on the injector assembly (2). Fuel Meter Body Assembly 3. Install the fuel injector assembly (12) into the fuel meter body injector socket. 4. Install the injector assembly retainer (11) and the injector retainer lock nuts (10). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the injector retainer lock nuts to 3 N.m (27 lb in). 5. Install the fuel meter body assembly. 6. Install the upper intake manifold assembly. 7. Tighten the fuel filler cap. 8. Connect the negative battery cable. 9. Inspect for leaks. 9.1. Turn ON the ignition for 2 seconds. 9.2. Turn OFF the ignition for 10 seconds. 9.3. Turn ON the ignition. Page 5261 C210 (Body Harness To Redundant Steering Wheel Controls Harness) Page 8049 1. Position the sight shield on the vehicle frame. 2. Install the push-pin retainers through the sight shield into the frame. Page 1509 Balance Shaft: Specifications Balance Shaft Driven Gear Bolt First Pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 35 degrees Balance Shaft Retainer Bolt ................................................................................................................ ................................................ 12 Nm (106 inch lbs.) Balance Shaft Bearing Journal Diameter - Rear ..................................................................................................................... 38.085 - 38.100 mm (1.4994 - 1.500 inch) Bushing Bore Diameter - Rear .......................................................................................................................... 0.050 - 0.088 mm (0.0020 - 0.0035 inch) Page 7096 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 8644 Page 6654 1. Install the heater core to the heater/vent module. 2. Install the heater core access cover. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the heater core access cover screws to 1.9 N.m (17 lb in). 3. Install the heater/vent module. Page 4856 Page 5646 C101 (Body Harness To Engine Harness) Part 3 C102 (Body Harness To Engine Harness) Page 9111 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 6509 Abbreviations And Meanings - Part 10 Page 646 Knock Sensor (KS) Page 938 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite the rotor segment when the driven gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. Page 7677 Abbreviations And Meanings - Part 5 Page 9351 Page 3188 Steps 16-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Page 7916 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 5025 Abbreviations And Meanings - Part 14 Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 9645 Abbreviations And Meanings - Part 26 Page 4809 Page 9774 Page 9356 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 1413 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.03-0.13 mm (0.001-0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Page 3134 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Page 4567 3. Install the brake rotor and wheel bearings, 2 wheel drive vehicles only. 4. Install the brake caliper and mounting bracket, 4 wheel drive vehicles. 5. Install the brake caliper, 2 wheel drive vehicles. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Refer to Vehicle Lifting. Brake Rotor Replacement - Rear Brake Rotor Replacement - Rear Tools Required ^ J42450-A Wheel Hub Resurfacing Kit Removal Procedure Notice: Refer to Brake Caliper Notice in Service Precautions. Important: Do not disconnect the brake hose from the caliper. Page 2470 Spark Plug: Specifications Spark Plug Torque Used heads 15 Nm 11 lb. ft. New aluminum heads 20 Nm 15 lb. ft. New iron heads 30 Nm 22 lb. ft. Page 5131 Abbreviations And Meanings - Part 24 Page 5022 Abbreviations And Meanings - Part 11 Page 1353 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 2184 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 6009 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Page 5759 C304 (Body Harness To LR Door Harness) (4-Door) Page 7702 Registered And Non-Registered Trademarks - Part 3 Page 4325 Electronic Components Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Raise and support the hood. 2. Remove the bolt from the right and the left vent grille end panels. 3. Lift up on the right and the left vent grille end panels to release the retaining clips. 4. Remove the right and the left vent grille end panels. 5. Remove the screws that secure the center vent grille panel to the cowl. 6. Remove the push-pin retainers that secure the center vent grille panel to the cowl. 7. Remove the center vent grille panel from the cowl. Installation Procedure Page 3386 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 9214 Page 2080 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 445 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 5617 Application Table Part 2 Page 79 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 2827 Floor Pedals Page 6425 Air Door Actuator / Motor: Description and Operation AIR TEMPERATURE ACTUATOR The air temperature actuator is a 3-wire bi-directional electric motor. Ignition 3 voltage, ground and control circuit enable the actuator to operate. The control circuit uses a 0-12 volt linear-ramped signal to command the actuator movement. The 0 and 12 volt control values represent the opposite limits of the actuator range of motion. The values in between 0-12 volts correspond to the positions between the limits. When the HVAC control module sets a commanded, or targeted, value, the control signal is set to a value between 0-12 volts. The actuator shaft rotates until the commanded position is reached. The module will maintain the control value until a new commanded value is needed. When full cold is selected, a low voltage, near ground, is applied to control circuit. When full hot is selected, a high voltage, 12 volts, is applied to the control circuit. Locations Engine, LR Page 9047 Compass Sensor Page 3634 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4071 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 6847 2. Install the SDM (2) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 12 N.m (106 lb in). 5. Install the SDM harness connector (3) to the SDM (2). 6. Install the CPA (4) to the SDM harness connector (3). 7. Tape the cut carpet to cover the SDM. 8. Install the floor console, if equipped. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 9227 2. Install the engine oil pressure sensor fitting, if removed. Tighten the engine oil pressure sensor fitting to 15 Nm (11 ft. lbs.). 3. Install the engine oil pressure sensor. Using the J41712, tighten the engine oil pressure sensor to 30 Nm (22 ft. lbs.). 4. Connect the engine oil pressure sensor electrical connector. 5. Install the distributor. 6. Check and adjust engine oil level. Page 2395 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 1812 5. Remove the camshaft sprocket bolts. 6. Remove the camshaft sprocket and the camshaft timing chain. 7. Remove the crankshaft sprocket using the J 5825-A. Page 2025 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 2747 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. Page 9459 Page 5068 Page 8700 Abbreviations And Meanings - Part 20 Locations Vehicle Speed Sensor: Locations Manual Transmission, LH Page 4105 5. Remove the clutch master cylinder from the dash panel. 6. Raise and support the vehicle. 7. Using the J 42371 remove the clutch line from the concentric slave cylinder. 8. Lower the vehicle. 9. Remove the clutch master cylinder. Installation Procedure 1. Install the clutch master cylinder. 2. Raise the vehicle. 3. Pull back on the connector sleeve and connect the clutch line to the concentric slave cylinder. 4. Lower the vehicle. 5. Install the clips securing the clutch line to the dash panel and heat shield. Page 9626 Abbreviations And Meanings - Part 7 Page 5321 C203 (Body Harness To IP Harness) Part 9 Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door LOCK ACTUATOR REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws (2) that retain the lock actuator (1) to the latch. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. INSTALLATION PROCEDURE Page 5316 C203 (Body Harness To IP Harness) Part 4 Page 5307 C116 C1 (Active Transfer Case Harness To Engine Harness) Page 5241 C116 C2 (Engine Harness To Active Transfer Case Harness) Page 9096 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 493 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 4788 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting bolt. Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). Page 2685 Abbreviations And Meanings - Part 5 Page 5606 Relay Block - Body Part 2 Locations Throttle Position Sensor: Locations Engine, LR Page 4042 Wiper Arm Replacement Wiper Arm: Service and Repair Wiper Arm Replacement WIPER ARM REPLACEMENT REMOVAL PROCEDURE 1. Mark the wiper park position on the windshield with a suitable non-permanent marker. 2. Remove the cover from the wiper arm nut. 3. Remove the wiper arm retaining nut. 4. Remove the wiper arm from the wiper transmission drive shaft. INSTALLATION PROCEDURE 1. Install the wiper arm onto the wiper transmission drive shaft. 1.1. Align the wiper arm with the marks made on the windshield. 1.2. Push the wiper arm down onto the wiper transmission drive shaft completely. NOTE: Refer to Fastener Notice in Service Precautions. Locations Locations View Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 8419 Sunroof Control Module C2 Page 4972 Page 5796 Splice Pack SP203 Part 2 Page 3728 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Page 9623 Abbreviations And Meanings - Part 4 Page 2927 Engine Harness Rear (4.3L) Page 6505 Abbreviations And Meanings - Part 6 Page 2059 Radiator: Service and Repair Radiator Replacement (4.3L) ^ Tools Required - J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Reposition the coolant recovery hose clamp from radiator. 3. Remove the coolant recovery reservoir hose from the radiator. 4. Using the J 38185 reposition the radiator inlet hose clamp from the radiator. 5. Remove the radiator inlet hose from the radiator. 6. Remove the fan shroud. 7. Using the J 38185 reposition the radiator outlet hose clamp from the radiator. 8. Remove the radiator outlet hose from the radiator. 9. Remove the engine oil cooler lines from the radiator. 10. Remove the transmission oil cooler lines from the radiator. Page 8753 Seat Adjuster Switch - Driver C2 (w/ 8-Way, w/o Memory) Service and Repair Tailgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - End Gate Removal Procedure 1. Remove the endgate window latch support. 2. Disconnect the electrical connectors, as needed. 3. Remove the clip that retains the endgate lock cylinder to the endgate. 4. Remove the lock cylinder from the endgate. Installation Procedure 1. Install the lock cylinder to the endgate. 2. Install the clip that retains the endgate lock cylinder to the endgate. 3. Connect the electrical connectors, as needed. 4. Remove the endgate window latch support. Page 7860 Tighten the lower latch bolt (2) to 10 N.m (89 lb in). 5. Install the wedge (6) to the door. 6. Install the anti-rotation screw (5) retaining the wedge to the door. Tighten the anti-rotation screw (5) to 2 N.m (18 lb in). 7. Complete installation of the upper latch bolt (4). Tighten the upper latch bolt (4) to 10 N.m (89 lb in). 8. Connect the latch rod (3) to the retainer on the latch control handle. 9. Install the door trim panel. Page 8118 Tighten the console to the vehicle retainers to 10 N.m (88 lb in). 7. Install the convenience tray to the armrest storage compartment. 8. Connect the instrument panel to console wiring harness connection 9. Install the passenger side toe-panel by firmly pressing the toe-panel into place. 10. Carefully press the wood shifter assembly close-out into place. The closeout panel will need to be rotated in order to fit over the shift handle 11. Install the front ashtray to the console by firmly pressing the ashtray into place. Console Replacement - Front Floor (Full-Length (Manual Trans) Console Replacement - Front Floor (Full Length (Manual Trans)) Removal Procedure 1. Remove the shift control lever. 2. Remove the cup holder insert. 3. Remove the screws that retain the trim plate to the console. 4. Remove the trim plate from the console. Page 791 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 121 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Page 5966 Power Steering Fluid Reservoir: Service and Repair (P Series) Power Steering Reservoir Replacement Off Vehicle (P Series) Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (4). 4. Remove the O-ring seal (3). 5. Remove the reservoir assembly (1) from the pump housing assembly (2). 6. Remove the O-ring seals (1) (4) (5). 7. Remove the magnet (3). Page 8823 1. Install the liftgate outside handle to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the liftgate outside handle to the liftgate. Tighten the bolts to 4 N.m (35 lb in). 3. Install the liftgate handle rod to the liftgate handle. 4. Engage the retainer. 5. Install the liftgate trim panel. Page 2624 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the air cleaner outlet resonator. 3. Disconnect the idle air control (IAC) valve harness connector. 4. Remove the IAC valve mounting screws. 5. Remove the IAC valve and O-ring from the throttle body assembly. CLEANING AND INSPECTION PROCEDURE 1. Clean the IAC valve O-ring sealing surface, pintle valve seat, and air passage. - Remove excess carbon deposits with a small amount of carburetor cleaner on a parts cleaning brush. Follow any instructions on the cleaner Page 371 Engine Harness Rear (4.3L) Page 8703 Abbreviations And Meanings - Part 23 Page 1036 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings component using the J 39400-A. 7. Install the engine coolant reservoir. 8. Install the PCM. Page 9086 Page 6264 2. Install the spare tire carrier to body side inner panel mounting bolts. Tighten Tighten the spare tire carrier to body side inner panel mounting bolts to 30 Nm (22 ft. lbs.). 3. Install the spare tire to the spare tire carrier. 4. Install the spare tire to the spare tire carrier mounting nut. 5. Install the spare tire cover. Page 1901 For vehicles repaired under warranty, use the table. Disclaimer Page 8751 Seat Adjuster Switch - Driver C1 (w/ 8-Way, w/o Memory) Part 2 Seat Adjuster Switch - Front Passenger C1 (w/ 8-Way, w/o Memory) Part 1 Page 7277 Abbreviations And Meanings - Part 3 Page 4755 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Page 1979 DISCLAIMER Page 9748 Window Switch - LR Page 4844 5. Install the nut retaining the positive battery cable to the generator. Tighten Tighten the positive battery cable nut to 17 N.m (13 lb ft). 6. Install the nut retaining the positive battery cable to the underhood fuse block. Tighten Tighten the positive battery cable nut to 10 N.m (89 lb in). 7. Connect the positive battery cable to the battery. Tighten Tighten the positive terminal bolt to 14 N.m (11 lb ft). 8. Connect the negative battery cable to the battery. Page 4700 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure 1. Remove the brake shoes. 2. Disconnect the brake pipe. 3. Remove two bolts. 4. Remove the wheel cylinder. Installation Procedure 1. Install the wheel cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten the bolts to 13 Nm (115 inch lbs.). 3. Connect the brake pipe to the wheel cylinder. Tighten the brake pipe fitting to 21 Nm (16 ft. lbs.). 4. Install the brake shoes. 5. Bleed the brake system. Page 2832 Engine Coolant Temperature (ECT) Sensor Page 4881 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 769 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 8951 Page 7641 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Locations Steering Column Components Page 7111 Abbreviations And Meanings - Part 4 Sunroof Window Replacement With RPO Code CF5 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement With RPO Code CF5 SUNROOF WINDOW REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Open the sunshade panel. IMPORTANT: The sunroof must be in the fully closed position prior to removing the glass panel. 2. Remove the 4 screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Remove the sunroof window from the top of the vehicle. INSTALLATION PROCEDURE 1. Position the sunroof window (1) to the vehicle. 2. Install the screws (2) that retain the sunroof window (1) to the sunroof module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Perform the following steps in order to adjust the sunroof window. 3.1. Adjust the fit between the sunroof window and the roof opening. The fit should be equal on both sides. 3.2. Adjust the rear edge of the window slightly higher than the front edge in order to minimize wind noise. Tighten Tighten the sunroof window screws to 3 N.m (27 lb in). 4. Open and close the sunroof. 5. Inspect the fit of the sunroof window. Page 9521 Abbreviations And Meanings - Part 17 Page 3156 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Rear) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Raise the vehicle. 5. Clean all the fuel pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system. 6. Remove the fuel tank. 7. Disconnect the rear fuel feed pipe from the fuel filter inlet. 8. Disconnect the rear fuel return pipe from the chassis fuel return pipe (2). 9. Remove the fuel feed and return pipes from the retainers. 10. Cap the fuel pipes in order to prevent possible fuel system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel and evaporative emission (EVAP) pipes. 2. Connect the rear fuel return pipe to the chassis fuel return pipe (2). 3. Connect the rear fuel feed pipe to the fuel filter inlet. 4. Install the fuel feed and return pipes into the retainers. 5. Install the fuel tank. 6. Lower the vehicle. Page 2262 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 8265 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. 3. Install the actuator to the top of the latch. IMPORTANT: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 4. Install the 2 screws (2) that retain the actuator (1) to the latch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 0.75 N.m (6 lb in). Page 4868 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7059 Capacity Specifications Coolant: Capacity Specifications Engine Cooling System Capacity Automatic Transmission 11.1 liters 11.7 quarts Manual Transmission 11.3 liters 11.9 quarts Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 55 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 850 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 6044 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9953 7. Remove the washer pumps and grommets from the solvent container. INSTALLATION PROCEDURE 1. Install the washer pumps and grommets onto the solvent container. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the solvent container onto the vehicle with the screw. Page 4254 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 9545 Steps 3-5 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the shock absorber upper mounting nut. Hold the shock absorber stem with a wrench while backing the nut off. 3. Remove the retainer. 4. Remove the grommet. 5. Remove the shock absorber lower mounting bolts. 5.1. Pull the shock absorber out of the spring from below. 5.2. The lower grommet and the retainer are on the stem. 5.3. Replace the parts as necessary. 6. Remove the nuts, if damaged or worn. Installation Procedure 1. Install the retainer and the grommet on the stem. Fully extend the stem. 2. Install the shock absorber up through the lower control arm and the spring. Insert the stem end through the hole in the upper control arm frame bracket. 3. Install the grommet to the stem. 4. Install the retainer to the stem. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shock absorber upper nut. Page 2570 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 5283 C315 (Body Harness To Passenger Seat Assembly Pigtail Connector) 4-Door with Power Seats) Page 3002 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Chassis/Canister REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the rear evaporative emission (EVAP) pipe from the chassis EVAP pipe (1). 3. Remove the EVAP pipe from the retainers. 4. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel and EVAP pipes. 2. Connect the rear EVAP pipe to the chassis EVAP pipe (1). 3. Install the EVAP pipe into the retainers. 4. Install the fuel tank. Page 6060 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 9136 Abbreviations And Meanings - Part 14 Page 7852 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement Door Handle Replacement - Rear Inside Removal Procedure 1. Remove the door trim panel. 2. Remove the inside door handle rod (2). 3. Remove the inside door handle retaining rivets. 4. Remove the inside door handle from the door by sliding the handle rearward. Installation Procedure 1. Install the inside door handle to the door by sliding the handle forward. Ensure that the handle is properly seated. 2. Install the inside door handle retaining rivets. 3. Install the inside door handle rod (2). 4. Install the door trim panel. Page 6372 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling Page 297 7. Disconnect the main feed electrical connector (1). 8. Remove the sunroof switch from the vehicle. INSTALLATION PROCEDURE 1. Position the ground wire (2) to the header. 2. Install the ground screw (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ground screw to 1.5 N.m (13 lb in). 3. Connect the main feed electrical connector (1). 4. Connect the electrical connector (3). 5. Operate the function of the sunroof switch (4). 6. Install the switch into the motor/actuator trim cover (5). Page 5548 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 2530 Engine, LR Page 812 Abbreviations And Meanings - Part 21 Page 8203 3. Install one short front screw (1) and install one long rear screw in order to hold the garnish molding (3) in position. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the remaining screws including the one other short screw next to the motor/actuator. Tighten the screws to 1.5 N.m (13 lb in). 5. Install the 8 sunroof panel window garnish molding screw covers. Page 8601 5. Remove the seat back cardboard by unhooking the plastic clips from the lumber support. 6. Separate the seat back pad from the seat back frame. Installation Procedure 1. Install the seat back pad onto the seat back frame. 2. Install the seat back cardboard to the seat by hooking the plastic clips onto the lumbar support. 3. Pull the seat cover over the entire seat back. 4. Engage the J-strip at the base of the seat back. 5. Install the head restraint to the seat back. Seat Back Recliner Replacement - Front Seat Back Recliner Replacement - Front Page 749 Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. (CB Series) Power Steering Fluid Reservoir: Service and Repair (CB Series) Power Steering Reservoir Replacement -Off Vehicle (CB Series) Disassembly Procedure 1. Place the hydraulic pump (1) on a fixed, flat surface, with the shaft facing upward. 2. Insert a screwdriver into the retaining clip tab (3). 3. Using the screwdriver, force the retaining clip tab (3) outward. 4. Slide the reservoir clip (4) away from the hydraulic pump assembly (1). 5. Repeat the above steps to remove the second reservoir clip (4). 6. Remove the reservoir (2) from the hydraulic pump housing (1). 7. Remove the O-ring seal from the neck of the reservoir (2) or the hydraulic pump housing (1). Discard the O-ring seal. Assembly Procedure 1. Lubricate the new O-ring seal with power steering fluid. 2. Install the new O-ring seal onto the neck of the reservoir (2). 3. Install the reservoir (2) onto the hydraulic pump assembly (1). Ensure the reservoir neck is completely engaged onto the hydraulic pump assembly (1). 4. Align the feet of the reservoir with the sides of the hydraulic pump housing. 5. Install the new reservoir retaining clips (4) (supplied with the pump). Ensure the retaining clip tabs (3) fully engage with the hydraulic pump housing (1). Page 5848 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 862 Alignment: Description and Operation Thrust Angle Description Thrust Angles Description The front wheels aim or steer the vehicles. The real wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Page 4973 Page 9994 Wiper Motor: Service and Repair WIPER MOTOR REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the transmission from the wiper motor drive link using the J 39232. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the three screws and wiper motor from the vehicle. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 4951 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Specifications Oil Pan: Specifications Oil Pan Baffle Bolt ............................................................................................................................... ............................................... 12 Nm (106 inch lbs.) Transmission Bolt to Oil Pan ............................ ........................................................................................................................................ 47 Nm (35 ft. lbs.) Oil Pan Bolt and Nut in Sequence (1 - 12) ............................................................................................................................................... 25 Nm (18 ft. lbs.) Page 6479 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Power Mirror Switch Replacement Power Mirror Switch: Service and Repair Power Mirror Switch Replacement POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 8710 Registered And Non-Registered Trademarks - Part 3 Service and Repair Air Duct: Service and Repair AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel. 2. Remove the driver side air distributor duct screws. 3. Remove the cowl side air distributor duct screws. 4. Remove the air distributor duct from the instrument panel. INSTALLATION PROCEDURE 1. Install the air distributor duct to the instrument panel. 2. Install the cowl side air distributor duct screws. Page 5324 C204 (Floor Shifter Harness To Body Harness) (Utility and Crew Cab) Page 3023 Step 8 Page 1695 Oil Filter Adapter: Service and Repair Oil Filter Bypass Valve Replacement Oil Filter Bypass Valve Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the oil filter (2WD vehicle). 4. Remove the oil filter adapter. 5. Using a suitable prying tool remove the oil filter bypass valve. 6. Clean and inspect valve bore for damage. Installation Procedure 1. Install a NEW oil filter bypass valve using the following procedure: 1.1. Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve. 1.2. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. 1.3. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart. 2. Install the oil filter adapter (RWD vehicle) or the remote oil filter pipe adapter (4WD vehicle). 3. Install the oil filter (RWD vehicle). 4. Lower the vehicle. Page 9551 Steps 6-10 Page 9797 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 2989 Evaporative Emission (EVAP) Canister Vent Solenoid And Canister (4-Door Utility And Pickup) Page 6913 IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor can no longer be properly mounted. 7. Perform the following steps in order to complete the first fastener repair: 7.1. Remove and discard the improperly installed rivet. 7.2. Reattach sensor with new rivet. 8. Perform the following steps in order to complete the second fastener repair: 8.1. Remove the improperly installed rivet. 8.2. Enlarge the mounting holes (1) in the lower radiator support to 9.0 mm (0.35 in). 8.3. Insert and properly seat the rivnut. 8.4. Install sensor with screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 8.0 N.m (71 lb in). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the inflatable restraint front end discriminating sensor horizontally to the lower radiator support surface. Ensure that the arrow is pointing toward the front of the vehicle. 3. Install the inflatable restraint front end discriminating sensor mounting rivets (GM P/N 15715058). Page 9103 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 4724 6. Remove the rear park brake cable from the equalizer. 7. Using the J37043 (1), collapse the locking finger for the rear park brake cable. 8. Slide the inner park brake cable to the rearward. 9. Remove the park brake cable from the frame retainers. 10. Remove the park brake cable from the rear axle housing retainers, if needed. Page 9618 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 3754 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 167 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. 1. Remove the left instrument panel sound insulator from the vehicle. 2. Remove the lower instrument panel sound insulator from the vehicle. 3. Disconnect the electrical connectors from the body control module. 4. Bend the 2 snap retainers back slightly and pull the body control module from the bracket at an angle. INSTALLATION PROCEDURE 1. Install the body control module to the bracket at an angle under the wide hook retainer, with the label facing away from the bracket. 2. Apply pressure on the left side of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 3. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. 4. Connect the electrical connectors to the body control module. Be sure to connect the brown connector last. 5. Install the lower instrument panel sound insulator to the vehicle. 6. Install the left instrument panel sound insulator to the vehicle. 7. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The scan tool 8. Perform the BCM Programming. See: Testing and Inspection/Programming and Relearning 9. Clear the diagnostic trouble codes (DTCs). Page 4679 Hydraulic Control Assembly - Antilock Brakes: Description and Operation BPMV Hydraulic Flow This vehicle is equipped with the Kelsey-Hayes EBC325 antilock braking system. The vehicle is equipped with the following braking enhancement systems: ^ Antilock Brake System (ABS) ^ Dynamic Rear Proportioning (DRP) The following components are involved in the operation of the above systems: ^ Electronic Brake Control Module (EBCM) - The EBCM controls the system functions and detects failures. The ESCM contains the following components: System Relay - The system relay is internal to the EBCM. The system relay is energized when the ignition is ON. The system relay supplies battery positive voltage to the solenoid valves and to the pump motor. This voltage is referred to as system voltage. - Solenoids - The solenoids are commanded by the EBCM to operate the appropriate valves in the brake pressure modulator valve, ^ Brake Pressure Modulator Valve (BPMV) - The BPMV uses a 3-circuit configuration to control the left front wheel, the right front wheel, and the combined rear wheels. The BPMV directs fluid to the left front and right front wheels independently. The BPMV directs fluid to the two rear wheels on a single hydraulic circuit. The BPMV contains the following components: Pump Motor - Three isolation valves (one for each hydraulic circuit) - Three dump valves (one for each hydraulic circuit) - A front low-pressure accumulator - A rear low-pressure accumulator ^ Wheel Speed Sensors (WSS) - As the front wheels spin, a toothed ring located at each wheel hub interrupts a magnetic field in the wheel speed sensors. This causes the wheel speed sensors to generate an AC signal. The EBCM uses this AC signal to calculate the wheel speed. The wheel speed sensors are replaceable only as part of the wheel hub and bearing assemblies. Any imperfections in the toothed ring, such as a missing or damaged tooth, can cause an inaccurate WSS signal. ^ Vehicle Speed Sensor (VSS) - The input signal for rear wheel speed originates with the VSS. The Powertrain Control Module (PCM) receives rear wheel speed information from the VSS and supplies this information to the EBCM via a serial data message. Page 9806 Conversion English/Metric Part 2 Page 5618 Application Table Part 3 Page 8577 Seat Lumbar Switch - Front Passenger Part 2 Page 2442 For vehicles repaired under warranty, use the table. Disclaimer Page 5088 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9350 Page 5724 C119 (4WAL/SIR Harness To AIR Jumper Harness) Page 548 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 946 Tighten the distributor clamp bolt to 25 N.m (18 lb ft). 8. Install the distributor cap. 9. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. 13. Repeat installation procedure 2 if the malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the MIL is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. Page 3325 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots » turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Page 8990 Abbreviations And Meanings - Part 2 Page 5142 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Schematics Page 4763 9. Remove the vacuum booster mounting nuts. 10. Remove the vacuum booster assembly. 11. Remove the gasket. Installation Procedure 1. Install the vacuum booster assembly and the gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vacuum booster mounting nuts on the vacuum booster. Tighten the vacuum booster mounting nuts to 40 Nm (30 ft. lbs.). 3. Install the steering column support bracket. 4. Install the stop lamp switch and the pushrod to the brake pedal pin. Page 8214 Removal Procedure 1. Remove the left front door sill trim plate. 2. Remove the body hinge pillar trim panel from the vehicle. Installation Procedure 1. Install the body hinge pillar trim panel to the vehicle. 2. Install the left front door sill trim plate. Trim Panel Replacement - Right Hinge Pillar Trim Panel Replacement - Right Hinge Pillar Removal Procedure 1. Remove the right front door sill trim plate from the vehicle by gently pulling it upward. 2. Remove the right-side instrument panel sound insulator. 3. Remove the body hinge pillar trim panel. Installation Procedure 1. Install the body hinge trim panel. 2. Install the right-side instrument panel sound insulator. Page 4401 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 8756 Seat Adjuster Switch - Driver/Front Passenger (w/ Memory) Part 2 Page 2202 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 8565 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (w/ 6-Way) Part 1 Page 3248 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Open the rear side door window. 2. Remove the rear side door window weatherstrip. Start the at butt joint and pull the weatherstrip from the window opening. Installation Procedure 1. Install the rear side door weatherstrip. 2. Locate the butt joint at the bottom center of the window opening and set the weatherstrip around the window opening. Page 7820 Front Door Striker: Service and Repair Striker Replacement - Upper Striker Replacement - Upper Removal Procedure 1. Remove the rear side door upper latch striker cover, use a flat-bladed tool to release the retainers from the roof panel. Page 3235 Throttle Position (TP) Sensor Page 5224 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 9873 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 8366 WA379E/86 - WA382E/11 Page 8155 Glove Compartment Lock Cylinder: Service and Repair KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Page 773 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Service and Repair Vacuum Controller: Service and Repair VACUUM CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel carrier. 2. Disconnect the electrical connector (4) from the vacuum control assembly (5). 3. Disconnect the vacuum harness connector from the vacuum control assembly. 4. Remove the vacuum control assembly retaining screws. 5. Remove the vacuum control assembly from the vehicle. Page 3719 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Page 747 Page 984 Drive Belt Whine Diagnosis Step 1 - 5 Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The number(s) refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Page 9529 Abbreviations And Meanings - Part 25 Page 9239 3. Install the electrical connector. 4. Install the knee bolster trim panel. Locations Ignition Control Module: Locations Engine Generator And Starter Page 8595 3. Install the seat adjuster rail to the seat frame with 2 nuts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 24 N.m (18 lb ft). 4. Install the cable (3) to the seat back pivot assembly. 5. Install the cable (3) to the pivot assembly bracket by tightening cable nut (2). 6. Install the cable cover bracket (2) to the seat back pivot assembly. 7. Install the 2 bolts (1). Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 2499 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module (BCM) C2 Part 1 Page 7105 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 3574 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module (BCM) C1 Part 1 Page 3403 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Page 506 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Page 1722 Oil Pan: Service and Repair Off Vehicle Oil Pan Replacement Removal Procedure 1. Remove the oil pan drain plug and drain the engine oil into a suitable container. Important: The low oil level sensor is not reusable. Use a NEW low oil sensor. 2. Remove and discard the engine oil level sensor (if applicable). 3. Remove the oil pan bolts and nuts. Page 4422 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4283 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 446 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Page 2421 3. Tighten the air cleaner cover wingnuts. Page 1769 4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure: 4.1. Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting. 4.2. Lubricate the seal with clean engine oil. 4.3. Install the power brake booster vacuum tube fitting in the upper intake manifold. 4.4. Turn and lock the power brake booster vacuum tube fitting in position. 5. Install a NEW seal on the fuel meter body assembly. 6. Lubricate the seal with clean engine oil. 7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold. Page 6571 4. Place the J 33019 in the hub bore. 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin. 6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing. CAUTION: Use care in order to prevent personal injury when striking the staking pin with a hammer. 7. Stake 3 locations on the bearing race 120 degrees apart as shown. IMPORTANT Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing. Page 7945 Hood Latch: Service and Repair Hood Latch Replacement - Secondary Hood Latch Replacement - Secondary Removal Procedure 1. Raise and support the hood. 2. Remove the bolts that retain the latch assembly to the hood. 3. Remove the secondary hood latch assembly from the hood. Installation Procedure 1. Install the secondary hood latch assembly to the hood. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the secondary hood latch bolts that retain the latch assembly to the hood. Tighten the secondary hood latch mounting bolts to 25 N.m (18 lb ft). Page 3451 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 6367 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: ^ General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle ^ Classify the failure of the wheel bearing with the aid of the illustrations. ^ Determine the cause of the wheel bearing failure. ^ Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Page 2920 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 250 Seat Horizontal Position Sensor - Driver (w/ Memory) Page 5106 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 586 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 5786 C601 (Body Harness To Door Harness, RH Front) (W/ Power Locks/Windows) Part 3 Page 5649 C106 (Forward Lamp Harness To Body Harness) Part 2 C106 (Forward Lamp Harness To Body Harness) (Export) Page 8680 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 2636 Page 5735 C203 (Body Harness To IP Harness) Part 9 Specifications Connecting Rod: Specifications Connecting Rod Nut First Pass ............................................................................................................................................. .................................................. 27 Nm (20 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 70 degrees Connecting Rod Side Clearance .................................................................................................................................... 0.15 - 0.44 mm (0.006 - 0.017 inch) Connecting Rod Side Clearance .................................................................................................................................... 0.15 - 0.44 mm (0.006 - 0.017 inch) Crankshaft Connecting Rod Journal Diameter .................................................................................................................... 57.116 - 57.148 mm (2.2487 - 2.2497 inch) Connecting Rod Journal Out-of-Round - Production ....................................................................................................................... 0.005 mm (0.0002 inch) Connecting Rod Journal Out-of-Round - Service ............................................................................................................................ 0.025 mm (0.0010 inch) Connecting Rod Journal Taper - Production ............................................................................................................................. 0.00508 mm (0.00030 inch) Connecting Rod Journal Taper - Service ......................................................................................................................................... 0.025 mm (0.0010 inch) Page 8969 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 8675 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 3443 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SM Caution In Service Precautions. 1. Disable the SIR system. 2. Remove the steering column trim covers. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. Page 711 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 4464 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 lbs.), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 9355 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 2872 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 4837 Negative: Service and Repair Battery Negative Cable Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the negative battery cable bolt from the frame. 4. Remove the negative battery cable bolt from the radiator support. 5. Remove the negative battery cable bolt from the block. Page 6875 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear REMOVAL PROCEDURE 1. Fold the rear seats forward. Lift the rear seat floor filler trim panels to access the center rear seat belt assembly. 2. Remove the center rear seat belt assembly retaining nuts from the vehicle. 3. Remove the center rear seat belt assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the center rear seat belt assembly to the vehicle. 2. Install the center rear seat belt assembly retaining nuts to the vehicle. 3. Install the center rear seat belt assembly retaining nuts to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the center rear seat belt assembly retaining nuts to 80 N.m (59 lb ft). Page 6031 Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Control Module C1 Page 6837 Knee Diverter: Service and Repair Knee Bolster Replacement KNEE BOLSTER REPLACEMENT REMOVAL PROCEDURE 1. Turn the ignition switch to the LOCK position. 2. Remove the left sound insulator. 3. Remove the knee bolster trim panel. 4. Remove the instrument panel accessory trim plate. 5. Remove the nuts that retain the knee bolster from the steering column support. 6. Remove the knee bolster from the studs. INSTALLATION PROCEDURE 1. Install the knee bolster to the studs. 2. Install the nuts that retain the knee bolster to the steering column support. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 10 N.m (89 lb in). 3. Install the instrument panel accessory trim plate. 4. Install the knee bolster trim panel. 5. Install the left sound insulator. Page 630 Engine Generator And Starter Page 703 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Transmission Extension Housing Rear Oil Seal Replacement Seals and Gaskets: Service and Repair Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transjel Lubricant Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON09 111 transmission fluid. Page 6918 Seat Belt Switch - LF Page 3246 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 9826 Abbreviations And Meanings - Part 12 Page 2716 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data line. The serial data line is the means by which the microprocessor-controlled modules in the vehicle communicate with each other. Once the scan tool is connected to the class 2 serial data line through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to check for diagnostic trouble codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7.0 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. On some vehicles, if the PCM is unable to communicate with the VTD system after the vehicle has started, the PCM will consider the VTD system to be malfunctioning. The PCM will enter a fail enable state and will command the security indicator to illuminate. When the PCM is in a fail enable state the vehicle will NOT stall or stop running. If the PCM is in a fail enable state when the ignition is switched OFF, the PCM will remain fail enable until communications with the VTD system has been restored. When the PCM is in a fail enable state the VTD system is NOT active and the vehicle will start. This feature is NOT available on all GM vehicle lines. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Class 2 serial data at terminal 2. - Common signal ground at terminal 5. CLASS 2 SERIAL DATA LINE The class 2 serial data line on this vehicle is a ring/star configuration. The following modules communicate on the class 2 serial data line: The body control module (BCM) - The driver information center (DIC) - The electronic brake control module (EBCM) - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The memory seat module-driver - The powertrain control module (PCM) - The radio - The transfer case shift control module DIAGNOSTIC ENABLE CIRCUIT W/NP1 The transfer case shift control module is equipped with the ability to store diagnostic information, which is useful to a technician in the event of module, component or wiring concerns. This information can be retrieved via the diagnostic enable circuit from the transfer case shift control module by way of flash codes, which are displayed on the three transfer case shift control switch buttons. These buttons are located on the instrument panel to the right of the steering wheel. For diagnosis of this circuit, refer to Diagnostic Starting Point - Transfer Case in Transfer Case-NVG 233-NP1. Page 9016 Registered And Non-Registered Trademarks - Part 1 Page 5407 Location View Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Page 2732 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 5518 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 4511 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot into the caliper housing bore by hand. 4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by hand. 5. Install the boot on the piston. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Removal Procedure Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 2607 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Page 9060 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Page 9587 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Service and Repair Tailgate Stop: Service and Repair Bumper Replacement - End Gate (Utility) Removal Procedure Important: Do not remove both liftgate side bumper bolts at the same time. This will cause the backing plate to fall into the body, resulting in additional time to perform the repair. 1. Remove the lower side bumper bolt. 2. Loosen the upper side bumper bolt in order to rotate the side bumper and spacer (if equipped) away from the lower side bumper bolt hole. 3. Install the lower side bumper bolt. 4. Tighten the bolt in order to hold the backing place in place. 5. Remove the upper side bumper bolt. 6. Remove the spacer (if equipped). 7. Remove the side bumper. Installation Procedure 1. Install the side bumper. 2. Install the spacer (if equipped). 3. Install the upper side bumper bolt. 4. Rotate the lower side bumper bolt until the threaded hole is properly aligned. 5. Remove the lower side bumper bolt. 6. Rotate the side bumper and spacer (if equipped) in order to align the threaded hole in the backing plate. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the lower side bumper bolt. Tighten the bolt to 22 N.m (16 lb ft). Page 5998 Tighten the power steering pump front mounting bolts to 50 Nm (37 ft. lbs.). 5. Install the power steering pump rear mounting bracket nut to the engine stud. Tighten the power steering pump rear mounting bracket nut to 41 Nm (31 ft. lbs.). 6. Install the filler neck tube. 7. Install the filler neck tube mounting bolt. Tighten the filler neck tube mounting bolt to 20 Nm (15 ft. lbs.). 8. Connect the lower secondary air injection reactor pipe to the check valve. 9. Install the lower secondary air injection reactor pipe bracket to the power steering pump bracket stud. 10. Install the power steering pump mounting bracket retaining nut. Tighten the power steering pump mounting bracket retaining nut to 41 Nm (31 ft. lbs.). 11. Connect the lower secondary air injection reactor pipe lower connection. Page 1174 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. Page 4930 Registered And Non-Registered Trademarks - Part 3 Page 1805 8. Remove the crankshaft balancer key. 9. Clean the components with cleaning solvent. 10. Dry the components with compressed air. 11. Inspect the camshaft timing chain for binding or wear. 12. Inspect the camshaft sprocket and the crankshaft sprocket for: ^ Broken teeth (1) ^ Damaged teeth (2) ^ Chipped teeth (3) ^ Worn teeth ^ Uneven wear on the edge of the teeth ^ Worn valleys between the sprocket teeth Page 2653 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7749 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper (Xtreme) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the foglamps. 3. Remove the push-pins that retain the fascia to the impact bar. 4. Remove the screws that retain the fascia to the fascia support. 5. Remove the fascia from the impact bar retainers. 6. Remove the fascia from the vehicle. Installation Procedure 1. Install the front fascia to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fascia screws to the impact bar retainers. Tighten the fascia screws to 1.9 N.m (17 lb in). 3. Install the push-pins that retain the fascia to the impact bar. 4. Connect the electrical connector to the foglamps. 5. Lower the vehicle. Page 9076 Page 4191 Flywheel: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission. 2. Remove the clutch assembly, if equipped. 3. Remove the engine flywheel bolts. 4. Remove the engine flywheel (automatic transmission) (1), if applicable. 5. Remove the engine flywheel (manual transmission) (2), if applicable. Important: If replacing the engine flywheel (manual transmission), then NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel. 6. Note the position of any flywheel weights for assembly (if applicable). 7. Clean and inspect all parts. Installation Procedure Important: If replacing the engine flywheel (manual transmission), note the position and length of the original flywheel weights (if applicable). Flywheel weights of the same length must be installed into the new engine flywheel in the same location as the old flywheel weights were in the old engine flywheel. Page 5662 C203 (Body Harness To IP Harness) Part 3 Page 2745 Manifold Absolute Pressure (MAP) Sensor Page 1490 4. Install the valve rocker arms and pushrods. 5. Install the lower intake manifold. Engine - Engine Rattle at 1,800-2,200 RPM's Timing Chain Tensioner: Customer Interest Engine - Engine Rattle at 1,800-2,200 RPM's Bulletin No.: 03-06-01-024C Date: August 30, 2006 TECHNICAL Subject: Rattle Noise In Engine (Install Timing Tensioner Kit) Models: 1996-2003 Chevrolet Astro, Blazer, Express, S-10, Silverado and P Models 1996-2003 GMC Jimmy, Safari, Savana, Sierra, Sonoma 1996-2001 Oldsmobile Bravada with 4.3L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 03-06-01-024B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a rattle-type noise coming from the engine at approximately 1800 to 2200 RPMs. Cause The spark, rattle-type noise may be caused by torsional vibration of the balance shaft. Correction If detonation noise is present, perform detonation/spark knock diagnostics first. Install a new tensioner assembly kit using the procedure below. Remove the engine front cover. Refer to SI for engine front cover removal procedure. Remove the crankshaft sensor reluctor ring and line up the timing marks on the crank gear and cam shaft gear. Remove the camshaft gear and chain. For model years 1996-1998, remove the crankshaft sprocket using J 5825-A. Pull the shipping pin and discard. Remove the nylon timing chain tensioner blade from the timing chain tensioner bracket. Position the bracket on the front of the engine. The upper two attaching holes of the bracket will line up with the center two engine front cover bolt holes. The lower bracket holes will line up with the engine front cover alignment holes. Page 4092 Wiring Harness: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 2774 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module (BCM) C3 Part 1 Page 1953 Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the PCM. Important: Do not disconnect wiring harness to PCM. 2. Using the J 38185 reposition the hose clamp. 3. Remove the hose from the coolant recovery reservoir. 4. Remove the coolant recovery reservoir retaining nuts. Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Page 8194 Trim Panel: Service and Repair Garnish Molding Replacement - Rear Upper GARNISH MOLDING REPLACEMENT - REAR UPPER TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Use the J 38778 in order to remove the rear header garnish molding. Insert the J 38778 and work along the front edge of the trim panel from one end to the other. 2. Remove the cargo lamp from the roof rear header garnish molding. INSTALLATION PROCEDURE 1. Install the cargo lamp from the roof to the rear header garnish molding. 2. install the roof rear header garnish molding to the vehicle. Garnish Molding Replacement - Side Door Lock Pillar RPO Code CF5 GARNISH MOLDING REPLACEMENT - SIDE DOOR LOCK PILLAR WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the front and rear door sill trim plates. 2. Remove the upper and lower front seat belt anchor bolts. Page 4486 Brake Caliper: Service and Repair Brake Caliper Replacement - Front (Dual Piston) Brake Caliper Replacement - Front (Dual Piston) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper hose bolt from the brake caliper. 4. Remove the 2 copper gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 5. Discard the 2 copper gaskets. 6. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 7. Remove the brake hose and washers from the brake caliper. 8. Remove the brake caliper guide pin bolts. Page 8211 1. Install the body side front lower trim panel to the vehicle. 2. Install the upper body side trim panel to the vehicle. 3. Feed the seat belt through the trim panel. 4. Install the screw that retains the upper body side trim panel to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 1.9 N.m (17 lb ft). 5. Install the jack storage cover (left side only). 6. Install the endgate or the liftgate opening door sill trim plate. 7. Install the coat hook. 8. Install the assist handle. 9. Install the rear seat belt anchor nut. Tighten Tighten the nut to 80 N.m (59 lb ft). 10. Install the upper and lower front seat belt anchor bolts. Tighten Tighten the bolts to 70 N.m (52 lb ft). Trim Panel Replacement - Body Side (4-Door Utility) Trim Panel Replacement - Body Side (4-Door Utility) Removal Procedure Page 7097 Arrows And Symbols Uses various symbols in order to describe different service operations Page 9651 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 3233 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 6092 Abbreviations And Meanings - Part 15 Page 5672 C209 (Dome Harness To Body Harness) Part 1 Page 7064 Engine - Engine Rattle at 1,800-2,200 RPM's Timing Chain Tensioner: All Technical Service Bulletins Engine - Engine Rattle at 1,800-2,200 RPM's Bulletin No.: 03-06-01-024C Date: August 30, 2006 TECHNICAL Subject: Rattle Noise In Engine (Install Timing Tensioner Kit) Models: 1996-2003 Chevrolet Astro, Blazer, Express, S-10, Silverado and P Models 1996-2003 GMC Jimmy, Safari, Savana, Sierra, Sonoma 1996-2001 Oldsmobile Bravada with 4.3L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 03-06-01-024B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a rattle-type noise coming from the engine at approximately 1800 to 2200 RPMs. Cause The spark, rattle-type noise may be caused by torsional vibration of the balance shaft. Correction If detonation noise is present, perform detonation/spark knock diagnostics first. Install a new tensioner assembly kit using the procedure below. Remove the engine front cover. Refer to SI for engine front cover removal procedure. Remove the crankshaft sensor reluctor ring and line up the timing marks on the crank gear and cam shaft gear. Remove the camshaft gear and chain. For model years 1996-1998, remove the crankshaft sprocket using J 5825-A. Pull the shipping pin and discard. Remove the nylon timing chain tensioner blade from the timing chain tensioner bracket. Position the bracket on the front of the engine. The upper two attaching holes of the bracket will line up with the center two engine front cover bolt holes. The lower bracket holes will line up with the engine front cover alignment holes. Page 2255 Intake Air Temperature (IAT) Sensor Page 780 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 852 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 939 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. Page 4523 Brake Pad: Service and Repair Brake Pads Replacement - Front (Dual Piston Caliper) Brake Pads Replacement - Front (Dual Piston Caliper) Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, using the appropriate tool, remove brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the front caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard pad. Page 5581 Fuse Block - I/P Part 3 Page 5800 Splice Pack SP402 Page 1236 Relay Block - Body Part 6 Page 3967 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 7428 Page 5695 C307 (Body Harness To RR Door Harness) (4-Door) Page 3642 13. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 14. Remove the 2-4 servo assembly from the transmission. 15. Inspect the 4th apply piston, the 2-4 servo converter, 2nd apply piston, and the piston inner housing for the following defects: ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install the new seals on the pistons and the servo cover. 2. Lubricate the seals with clean transmission fluid. 3. Install the 2-4 servo assembly into the 2-4 servo bore. 4. Install the servo cover and O-ring seal. 5. Install the J29714-A. Page 5742 C210 (Body Harness To Redundant Steering Wheel Controls Harness) Page 8210 5. Install the jack storage cover (left side only). 6. Install the endgate or the liftgate opening door sill trim plate. 7. Install the coat hook. 8. Install the assist handle. 9. Install the rear seat belt anchor nut. Tighten the nut to 80 N.m (59 lb ft). 10. Install the upper and lower front seat belt anchor bolts. Tighten the bolts to 70 N.m (52 lb ft). Trim Panel Replacement - Body Side (2-Door) TRIM PANEL REPLACEMENT - BODY SIDE (2-DOOR UTILITY) REMOVAL PROCEDURE 1. Remove the upper and lower front seat anchor bolts. 2. Remove the rear seat belt lower anchor nut. 3. Remove the assist handle. 4. Remove the coat hook. 5. Remove the endgate or the liftgate opening door sill trim plate. 6. Fold the rear seats down. 7. Remove the jack storage cover (left side only). 8. Remove the screw that retains the upper body side trim body side trim panel to the vehicle (left side only). 9. Remove the upper body side trim panel from the vehicle. 10. Feed the seat belt through the trim panel. 11. Remove the body side front lower trim panel from the vehicle. INSTALLATION PROCEDURE Page 5635 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 9113 Conversion English/Metric Part 1 Page 3090 Fuel Injector: Description and Operation The Multec 2 fuel injector assembly is a solenoid device controlled by the control module that meters pressurized fuel to a single engine cylinder. The control module energizes the high-impedance, 12 ohms, injector solenoid to open a normally closed ball valve. This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has four machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Specifications Backing Plate: Specifications Backing Plate Mounting Bolts 35 ft. lbs. Page 5674 C209 (Dome Harness To Body Harness) Part 3 Page 7466 The theft deterrent system is a feature on all base and uplevel radios. There is no need to program a security code into the radio as in past model years. The theft deterrent system now utilizes class 2 serial data to determine if the radio is in the appropriate vehicle. Each time the radio receives the "run" power mode message, it compares the VIN information it has stored to the VIN information received from a module on the class 2 serial data circuit responsible for transmitting that information. If a mis-match occurs, the radio display will indicate to the user the radio is locked. Once this takes place the radio will not respond to any button presses and become inoperative. The two scenarios able to cause this condition are: 1. A radio is installed from another vehicle 2. A module which communicates on the class 2 serial data circuit which supplies VIN information to the radio is replaced and not properly setup with the correct VIN information for that vehicle The only way to unlock the radio is by using a scan tool. Always refer to the diagnostic table for further information. Integral Multi Disc CD Changer (IMDX) The integral multi disc CD changer has the capability of storing and playing up to six (6) compact discs. The integral multi disc CD changer has a shock-absorbing system. Only under extreme operating temperatures or severe shock or vibration should the compact disc player skip or mute. If the customer travels an abnormally rough road, a skip condition may be normal. Test drive the vehicle on a normal road with a known good CD. If the condition is still present, replace the radio. The use of CD lens cleaner discs is not advised, due to the risk of contaminating the lens of the CD optics with lubricants internal to the CD mechanism. Single Disc Loading To operate the integral multi disc CD changer in the single play mode, press the "LOAD" button for less than two seconds. The LED to the right of the disc door will turn green to indicate the CD can be loaded. Insert the disc into the slot, label side up. The player will pull the disc in. Multi Disc Loading To operate the changer in the multi disc mode, press the "LOAD" button for more than two seconds and the LED to the right of the disc door will flash. Once the light stops flashing and turns green you can load a disc. Insert the disc into the slot, label side up. The player will pull the disc in. Once the disc is loaded, the light will begin flashing again. Once the light stops flashing and turns green you can load another disc. Removing CDs Use the eject button to remove a disc or discs. Perform the following to eject: To remove a single disc, press and release the eject button. The message "REMOVE CD" is displayed. - To remove multiple discs, press and hold the eject button for two seconds. An audible beep is heard and the LED to the right of the disc door begins to flash indicating a disc is being ejected. The message "REMOVE CD" is displayed. Radio Data System (RDS) All uplevel audio systems are equipped with technology known as the Radio Data System (RDS). RDS is a system that sends data along with the audio of the FM station you are currently tuned to. RDS is a standard that defines how a FM broadcast station may send digital data along with the audio program. Think of it as a one way wireless modem, allowing the broadcaster to send information about his program to your receiver. RDS data is carried in what is known as a "sub-carrier". A sub-carrier is a frequency that the FM broadcaster is authorized to use to send data or other audio programs that are not audible in the main audio program. RDS information can be used to display program information and to control the radio. To receive the RDS signal, all that is needed is an FM receiver with a RDS circuit. A special integrated circuit capable of dealing with the RDS signal is in the RDS circuit and passes it along to the receiver's microprocessor where it is decoded and acted upon. RDS Basic Information RDS basic information: RDS functions are provided in the FM broadcast band only. - RDS functions will only work with FM broadcast stations that are broadcasting RDS data. - Not all FM Broadcast stations broadcast RDS data or offer all of the RDS services. - RDS functions may not work properly when reception is weak, reception is of poor quality, or RDS is not implemented properly by the FM Broadcaster. In some cases, a radio station broadcasting incorrect information may cause the RDS features of the radio to appear to work improperly. Broadcast RDS information can be used in a variety of ways by the receiver and listener, but basically falls into two categories: Display and Control. Displaying Program Information RDS displays textual information such as: The name of the station. - The type of program. - General information such as artist and song title, call in phone numbers, etc. RDS is always on. When tuned to a non-RDS station, your radio will display frequency information as you would normally expect. When tuned to a RDS station, your radio will change from displaying the frequency of the FM station to displaying the call letters of the station or display the nickname of the station. This feature is known as the Program Service Name. Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nut 27 ft. lbs. Brake Master Cylinder JC1/JM3 1 in. Page 6707 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings component using the J 39400-A. 7. Install the engine coolant reservoir. 8. Install the PCM. Page 8674 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 9401 Abbreviations And Meanings - Part 14 Page 2911 Transmission Range Switch (W/ A/T) Page 9676 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 9029 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Light Switch Mounting Bolt 35 inch lbs. Page 5111 Abbreviations And Meanings - Part 4 Page 970 Locations Seat Belt Components Page 8228 Door Lock Cylinder Switch - Driver (w/o RKE) Page 8976 Equivalent - Decimal And Metric Part 2 Page 5341 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 2 Page 4348 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 4306 2. Install the following parts: 2.1. The O-ring on the vehicle speed sensor assembly. 2.2. The vehicle speed sensor assembly. 2.3. Tighten Tighten the bolt to 16 Nm (12 ft. lbs.). 3. Install the electrical connector to the vehicle speed sensor. 4. Lower the vehicle. Page 9359 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 3942 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 1406 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: ^ General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle ^ Classify the failure of the wheel bearing with the aid of the illustrations. ^ Determine the cause of the wheel bearing failure. ^ Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Page 8945 Page 5880 Disclaimer Page 6484 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 4681 Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the four EBCM bolts. Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM (2). 4. Install BPMV (3) to EHCU bracket (5). 5. Connect the two electrical harness connectors to the EBCM (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the BPMV (3). Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Bleed the brake system. Page 5096 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1915 4. Using a long screw driver, align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine. 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. - There may be a 6 cast into this pointer, indicating that the distributor is to be used on a 6 cylinder engine or an 8, indicating that the distributor is to be used on a 8 cylinder engine. - If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more. - If this is the case, repeat the procedure again in order to achieve proper alignment. 7. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 9737 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 4457 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (RWD Utility) Wheel Speed Sensor Replacement (RWD Utility) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. 9. Remove wheel speed sensor from hub and bearing assembly (5). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 2673 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 5300 C104 (Chassis Harness To Engine Harness) Page 8353 WA882K/90 - WA900J/59 Page 9440 For vehicles repaired under warranty, use the table. Disclaimer Page 9504 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 6752 A/C Low Pressure Switch Page 1684 Oil Filter: Specifications Oil Filter ............................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) Oil Filter Fitting .................................................. ...................................................................................................................................... 35 Nm (26 ft. lbs.) Page 7171 For vehicles repaired under warranty, use the table. Disclaimer Locations Body Harness to Cowl Page 1917 Distributor: Service and Repair Distributor Inspection 1. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 1.1. Remove the cap. 1.2. Place 1 lead from the DMM on a cap terminal. 1.3. Use the other lead in order to probe all other terminals and the center carbon ball. 1.4. Move the base lead to the next terminal. Probe all other leads. 1.5. Continue this procedure until you test all the secondary terminals. 1.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 3. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 4. Inspect the shaft for shaft-to-bushing looseness: 4.1. Inspect the housing for cracks or damage. 4.2. Insert the shaft in the housing. 4.3. If the shaft wobbles, replace the housing assembly. Page 8523 Head Rest: Removal and Replacement Head Restraint Replacement - Front Seat Removal Procedure Depress the retainers located in the top of the seat back. Pull upward in order to remove the head restraint at the same time. Installation Procedure Push the head restraint into the retainers at the top of the seat, ensuring that the head restraint locks into place. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 5233 C104 (Chassis Harness To Engine Harness) Page 614 Page 6550 Cabin Air Filter: Service and Repair This vehicle does not use a factory installed Cabin Air Filter. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 1904 5. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 6. Line up the square-cut hole in the vane wheel with the camshaft position (CMP) sensor. 7. Remove the two screws that hold the CMP sensor. 8. Discard the screws. Page 7382 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 3567 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 8559 Seat Horizontal Position Sensor - Driver (w/ Memory) Page 8584 2. Connect the electrical connector to the switch. 3. Install the trim panel to the seat with the 3 screws. 4. Install the seat to the vehicle. Page 8887 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Side Door (Extended Cab (Third Door)) Weatherstrip Replacement - Rear Side Door (Extended Cab (Third Door)) Removal Procedure 1. Remove the top and bottom push-pin retainers from the rear side door weatherstrip. 2. Remove the weatherstrip from the rear door by gently pulling the weatherstrip away from the door. Installation Procedure 1. Install the weatherstrip to the rear side door by pressing the weatherstrip firmly into place. 2. Install the top and bottom push-pin retainers to the rear side door weatherstrip. Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the transmission drive link from the wiper motor crank arm using the J 39232. 4. Remove the transmission screws. 5. Remove the transmission from the vehicle through the access openings in the top of the cowl. INSTALLATION PROCEDURE 1. Install the transmission to the vehicle. Diagrams Fuel Tank Pressure (FTP) Sensor Page 4892 Conversion English/Metric Part 2 Page 2316 Mass Air Flow (MAF) Sensor Page 9075 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 2919 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 8698 Abbreviations And Meanings - Part 18 Page 6464 Page 5016 Abbreviations And Meanings - Part 5 Page 3563 Electronic Components OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 6457 Page 4041 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 1211 Fuse Block - Underhood Connector C1 Part 2 Page 2556 Disclaimer Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 4565 4. Remove the brake caliper and mounting bracket, 4 wheel drive. 5. Remove the retaining ring, 4 wheel drive vehicles only. 6. Remove the brake rotor, 4 wheel drive vehicles only. Page 4067 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 4957 Park Neutral Position (PNP) Switch Page 8372 WA528F/76 - WA5322/33 Page 8504 4. With the palm of the hand, remove the sunroof window from the top of the slider arms. INSTALLATION PROCEDURE 1. With the palm of the hand, position the sunroof window to the slider arm. IMPORTANT: The sunroof window is self locating to the slider arm. 2. Install the 4 sunroof window screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof window screws to 4 N.m (35 lb in). 3. Close the sunroof window. 4. Inspect the fit of the sunroof window to the outer periphery of the sunroof panel window seal. Page 1754 Important: The lower intake manifold gasket must be installed while the adhesive is still wet to the touch. 2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head. Notice: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage. Important: The lower intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch. 3. Apply a 5 mm (0.197 inch) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the front top of the engine block. 4. Extend the adhesive bead 13 mm (0.50 inch) onto each lower intake manifold gasket. 5. Apply a 5 mm (0.197 inch) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the rear top of the engine block. 6. Extend the adhesive bead 13 mm (0.50 inch) onto each lower intake manifold gasket. Page 1620 accessory component bracket. Page 2695 Abbreviations And Meanings - Part 15 Page 9739 Registered And Non-Registered Trademarks - Part 2 Page 7118 Abbreviations And Meanings - Part 11 OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 7117 Abbreviations And Meanings - Part 10 Page 8682 Abbreviations And Meanings - Part 2 Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 3970 Disclaimer Page 6869 3. Remove the bolt that retains the upper seat belt anchor plate to the vehicle. 4. Remove the body side trim panel. 5. Guide the seat belt through the opening in the body side trim cover. 6. Remove the bolt that retains the seat belt retractor assembly to the vehicle. 7. Remove the seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE Page 5703 C411 (Body Harness To Endgate Harness) Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Light Switch Mounting Bolt 35 inch lbs. Page 522 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 712 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Service and Repair Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 8493 8. Remove the old foam tape and apply new foam tape to the upper frame assembly. IMPORTANT: When applying new foam tape, overlap the foam tape at a screw hole to ensure proper sealing of the screw holes. 9. Remove the sunroof window track assembly. INSTALLATION PROCEDURE 1. Install the sunroof window track assembly to the new frame. 2. Position the upper frame to the roof panel. 3. Position the lower frame to the upper frame. IMPORTANT: The lower frame front needs to be positioned to the headliner first. Ensure the electrical wiring is positioned away from the upper and lower frame. 4. When the front (2) is positioned, raise the rear of the lower frame into position. 5. Install the lower to upper frame attachment screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws (1) to 1.5 N.m (13 lb in). 6. Connect the electrical connector to the motor. 7. Install the silver motor screw. Tighten Tighten the screw to 4.0 N.m (35 lb in). 8. Close the sunroof window. 9. Water test the sunroof assembly. Refer to Water Hose Test in Waterleaks. 10. Install the sunroof panel window garnish molding. Page 7738 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. 1. Remove the left instrument panel sound insulator from the vehicle. 2. Remove the lower instrument panel sound insulator from the vehicle. 3. Disconnect the electrical connectors from the body control module. 4. Bend the 2 snap retainers back slightly and pull the body control module from the bracket at an angle. INSTALLATION PROCEDURE 1. Install the body control module to the bracket at an angle under the wide hook retainer, with the label facing away from the bracket. 2. Apply pressure on the left side of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 3. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. 4. Connect the electrical connectors to the body control module. Be sure to connect the brown connector last. 5. Install the lower instrument panel sound insulator to the vehicle. 6. Install the left instrument panel sound insulator to the vehicle. 7. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The scan tool 8. Perform the BCM Programming. See: Testing and Inspection/Programming and Relearning 9. Clear the diagnostic trouble codes (DTCs). Page 1234 Relay Block - Body Part 4 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Locations Electronic Components Page 5461 For vehicles repaired under warranty, use the table. Disclaimer Page 7625 Page 8991 Abbreviations And Meanings - Part 3 Page 3175 Page 4031 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 102 Heated Seat Control Module Driver/Front Passenger (Part of the Heated Seat Control Module) Driver/Front Passenger (Part of the Heated Seat Assembly) Page 1732 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the sensor and Distributor before removal. Do not allow debris to enter the engine. 1. Remove the distributor. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor using the J 41712. Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 4. Remove the engine oil pressure sensor fitting, if necessary. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the fitting and/or the engine oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. Page 717 Page 5018 Abbreviations And Meanings - Part 7 Locations Floor Pedals Page 1181 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 1456 8. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Page 4282 Park Neutral Position (PNP) Switch Page 3730 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the transmission oil cooler (TOC) lines from the radiator. On vehicles equipped with a 4.3L engine and 4WD, it may be necessary to gain access to the lower cooler line (2) through the right side wheel well opening. 2. Raise the vehicle. 3. For vehicles equipped with a 2.2L engine, remove the nut securing the cooling line to the engine. 4. For vehicles equipped with a 4.3L engine, remove the clip and stud securing the cooler line to the engine. 5. Support the transmission with a transmission jack. 6. Remove the exhaust crossover pipe and the transmission support assembly. Page 8409 Memory Seat Module - Driver C3 Page 9418 Registered And Non-Registered Trademarks - Part 4 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 9591 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 9731 Abbreviations And Meanings - Part 21 Page 4526 3. Install inboard brake pad. 4. Remove the brake caliper from the support. Notice: Refer to Brake Hose Installation Notice in Service Precautions. 5. Install the brake caliper. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Refer to Vehicle Lifting. 8. Fill the brake master cylinder to the proper level. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Burnish the new brake pads. Page 5977 Power Steering Line/Hose: Service and Repair Power Steering Return Hose Replacement Power Steering Return Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the air cleaner assembly. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering return hose from the power steering pump (for vehicles without a power steering cooler). 4. Disconnect the power steering gear return hose from the power steering cooler, if equipped. 5. Disconnect the wiring harness clip from the power steering return hose at the power steering gear. 6. Disconnect the power steering gear return hose from the power steering gear. 7. Remove the power steering gear return hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Locations Power Seat Motor: Locations Seat Motors (8-Way w/o Memory) Description and Operation Door Switch: Description and Operation DOOR LATCH, DOOR JAMB SWITCHES The theft deterrent system uses the door latch switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. Page 9843 Registered And Non-Registered Trademarks - Part 2 Page 9600 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 7489 Speaker - RR Door (4-Door Utility) Locations Left Hand Side Of Instrument Panel Page 4117 Clutch Start Switch Page 4267 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 8371 WA526F/72 - WA528F/76 Page 3611 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. IP Fuse Block Details Fuse Block: Application and ID IP Fuse Block Details Location View Application Table Part 1 Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 5497 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 9721 Abbreviations And Meanings - Part 11 Page 7643 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Locations Cruise Control Module (CCM) Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 4976 Page 6085 Abbreviations And Meanings - Part 8 Page 6101 Abbreviations And Meanings - Part 24 Page 4938 Alternator: Service and Repair Generator Replacement. REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. Remove the heater hose brace bolt from the generator. 4. Remove the generator mounting bolts. 5. Remove the generator from the mounting bracket. 6. Disconnect the generator electrical connector. Page 4510 5. Remove the piston seal from the caliper bore. Do not use a metal tool. 6. Remove the bleeder valve and bleeder valve cap from the caliper body. 7. Remove the guide pins and guide pin sleeves from the anchor bracket. 8. Clean the following components with denatured alcohol. ^ The bleeder valve ^ The caliper bore ^ The caliper passages ^ The piston ^ The lining contact area on the anchor bracket. 9. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 10. Replace the piston or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore. Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Notice: Refer to Fastener Notice in Service Precautions. 11. Replace the bleeder valve cap. Tighten the bleeder valve to 12 Nm (110 inch lbs.). Assembly Procedure Page 8635 Page 7660 Equivalent - Decimal And Metric Part 2 Page 9370 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Page 8153 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Locations Steering Column Components Page 7294 Abbreviations And Meanings - Part 20 Page 1538 6. Route the heater cord (4WD). 7. Fill the cooling system. 8. Inspect the cooling system for leaks. Page 9706 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6568 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Use the following procedure in order to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: 7.1. Remove the forcing screw from the J 41552. 7.2. Ensure that the puller tangs still engage in the rotor slots. 7.3. Invert the assembly onto a solid flat surface or blocks. 8. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. V7 - Direct Mount CLUTCH ROTOR AND/OR BEARING REMOVAL (V7 - DIRECT MOUNT) TOOLS REQUIRED - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 41790 Compressor Holding Fixture 1. Remove the A/C compressor from the vehicle. 2. Clamp J 41790 in a vise and attach the A/C compressor to J 41790. Strut Replacement - Liftgate Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Strut Replacement - Lift Gate Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the liftgate struts using a small flat-bladed tool. 3. Remove the upper end of the liftgate struts from the ball joint. 4. Remove the lower end of the liftgate struts from the ball joint. 5. Remove the liftgate struts from the liftgate. Installation Procedure 1. Position the liftgate struts to the liftgate. 2. Install the upper end of the liftgate struts to the ball joint. Press in to place until fully seated. Page 7877 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Side Door (Extended Cab (Third Door)) Weatherstrip Replacement - Rear Side Door (Extended Cab (Third Door)) Removal Procedure 1. Remove the top and bottom push-pin retainers from the rear side door weatherstrip. 2. Remove the weatherstrip from the rear door by gently pulling the weatherstrip away from the door. Installation Procedure 1. Install the weatherstrip to the rear side door by pressing the weatherstrip firmly into place. 2. Install the top and bottom push-pin retainers to the rear side door weatherstrip. Page 3003 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Engine/Chassis REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the chassis evaporative emission (EVAP), fuel feed, and return pipes (1) at the engine compartment EVAP, fuel feed, and return pipes. 3. Remove the transmission. 4. Remove the EVAP/fuel pipe retainer clip (2) from the left cylinder head. 5. Disconnect the EVAP pipe (1). 6. Remove the EVAP pipe from the retainers. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. Page 3449 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 6053 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 4073 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 9546 Steps 6-8 Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers that retain the insulator to the hood. 2. Remove the insulator from the hood. Installation Procedure 1. Install the insulator to the hood. 2. Install the retainers to the hood. Page 3830 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Locations Shift Solenoid: Locations Steering Column Components Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 7298 Abbreviations And Meanings - Part 24 Page 9664 Page 176 Powertrain Control Module (PCM) Connector C1 Part 2 Page 5333 C211 (Steering Column Harness To Body Harness) Part 5 Page 4575 Important: Do NOT refinish the brake rotors in order to correct any of the following complaints: ^ Growl or squeal brake noise ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the rotor braking surface ^ Rotor discoloration Refinish the brake rotors ONLY when one or more of the following conditions exist: ^ Groove depth in excess of specification ^ Severe scoring of the rotor braking surface ^ Brake pulsation caused by the following: Lateral runout in excess of specification - Brake rotor thickness variation in excess of specification - Corrosion or pitting that is deeper than the rotor braking surface 1. Use the J42450-A in order to clean the wheel bearing/hub. 2. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor. 3. Use the J41013 in order to THOROUGHLY clean the rust from the brake rotor flange. 4. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 5. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor finisher, if available, in order to create a non-directional braking surface. 6. Clean the braking surfaces with GM P/N 12377981, Canadian P/N 10953463, or equivalent brake parts cleaner. Page 4859 Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 2689 Abbreviations And Meanings - Part 9 Engine/Transmission - Flexplate/Flywheel Replacement Flex Plate: Technical Service Bulletins Engine/Transmission - Flexplate/Flywheel Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-003 Date: February, 2003 INFORMATION Subject: Flywheel/Flexplate Replacement Models: 2003 Passenger Cars and Light Trucks When replacing the starter for any reason, the flywheel/flexplate should be inspected before replacement. The flywheel/flexplate should be turned a full 360 degrees and inspected for missing or broken teeth or signs of starter milling on the sides of the teeth before replacement. No flywheel/flexplate should be replaced without a visual defect. The majority of flywheel/flexplates returned to GM after replacement under warranty show no signs of damage or defect. Disclaimer Page 577 Mass Air Flow (MAF) Sensor Page 1010 Cabin Air Filter: Service and Repair This vehicle does not use a factory installed Cabin Air Filter. Page 5713 C101 (Body Harness To Engine Harness) Part 3 C102 (Body Harness To Engine Harness) Page 8754 Seat Adjuster Switch - Front Passenger C2 (w/ 8-Way, w/o Memory) Page 7974 Endgate Harness Routing View Page 1648 2. Install the engine mount and shield to the engine. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine mount to engine bolts. Tighten the engine mount to engine bolts to 54 Nm (40 ft. lbs.). 4. Install the engine mount frame bracket to the frame. 5. Install the engine mount frame bracket bolts. Tighten the engine mount frame bracket bolts to 45 Nm (33 ft. lbs.). 6. Lower the engine and remove the jack. 7. Install the engine mount through-bolts and nuts. Tighten the through-bolts or the nuts to the following: ^ Tighten the through-bolts to 74 Nm (55 ft. lbs.). ^ Tighten the nuts to 63 Nm (46 ft. lbs.). Page 8953 Specifications Compression Check: Specifications Compression Pressure Limit ............................................................................................................... ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest. Page 1035 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the PCM. 3. Remove the engine coolant reservoir. 4. Remove the nuts (4) from the A/C refrigerant filter (1). IMPORTANT:The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 5. Remove the A/C refrigerant filter (1) from the evaporator tube. INSTALLATION PROCEDURE 1. Coat the new O-rings (2) with 525 viscosity refrigerant oil. 2. Install the new O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (1) to the evaporator tube with the flow arrow pointing towards the evaporator. 4. Install the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the nuts to..............15 N.m (11 lb ft). Page 2456 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite the rotor segment when the driven gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. Service and Repair Clutch Slave Cylinder: Service and Repair Concentric Slave Cylinder Removal Procedure 1. Remove the transmission. 2. Remove the 2 bolts securing the concentric slave cylinder to the clutch housing. 3. Remove the slave cylinder from the transmission input shaft. If required, the bearing can be removed from the slave cylinder for replacement. Installation Procedure 1. Position the slave cylinder to the transmission input shaft. Ensure that the bleed screw and the coupling are positioned toward the transmission ports. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure the concentric slave cylinder to the clutch housing with 2 bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the transmission. Page 5748 C217 (Body Harness To IP Harness) Page 5533 Abbreviations And Meanings - Part 12 Page 2935 Park Neutral Position (PNP) Switch Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 2112 Muffler: Service and Repair Muffler Replacement (Utility) Removal Procedure Caution: Refer to Protective Goggles and Gloves Caution in Service Precautions. Notice: Refer to General Vehicle Lifting and Jacking Notice in Service Precautions. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the catalytic converter to muffler flange nuts. 3. Disconnect the insulator from the tail pipe hanger. 4. Disconnect the insulators from the muffler hanger (4-door utilities). Specifications Fuel Gauge Sender: Specifications Page 1055 Hose/Line HVAC: Service and Repair Evaporator Tube EVAPORATOR TUBE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the battery. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube retaining screw. 4. Remove the evaporator tube clip from the accumulator. 5. Remove the evaporator tube from the evaporator. 6. Remove the O-ring seal and discard. 7. Remove the lower radiator hose. 8. Remove the evaporator tube from the condenser. 9. Remove the O-ring seal. INSTALLATION PROCEDURE 1. Install a new O-ring seal. Engine Mount Replacement - Left Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When single mount breaks, the remaining mounts are subjected to abnormally high stresses. Refer to Engine Mounting Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the underbody shields, if equipped. 3. Remove the engine mount through-bolt and nut for the side being replaced Notice: Refer to Engine Lifting Notice in Service Precautions. 4. Using a jack on the square tab (left side shown) at the rear of the engine block, raise the engine. In order to access the square tab on the right side remove the starter. 5. Raise the engine only enough to remove the engine mount. Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the Data Link Communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Page 6856 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 7438 Page 1855 Steps 18-23 Page 6516 Abbreviations And Meanings - Part 17 Page 3826 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 9495 Conversion English/Metric Part 1 Page 4485 8. Install the front brake hose fitting, the 2 new gaskets and the brake hose fitting bolt. Tighten the front brake hose bolt to 54 Nm(40 ft. lbs.). 9. Fill the brake master cylinder to the proper level. 10. Bleed the brake caliper. 11. Inspect the brake system for leaks. 12. Install the tire and wheel assembly. 13. Lower the vehicle. Refer to Vehicle Lifting. Page 7683 Abbreviations And Meanings - Part 11 Page 1412 The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Fastener Tightening Specifications (CF5) Luggage Rack: Specifications Fastener Tightening Specifications (CF5) Fastener Tightening Specifications (CF5) Page 9597 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4693 5. Install the lubricated seals, make sure they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully tap the reservoir retaining pins into place to secure the reservoir. 8. Install the cover on the reservoir. 9. Remove the master cylinder from the vice. 10. Install the master cylinder. Page 4273 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the 2 halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery. NOTE: Refer to Handling ESD Sensitive Parts Notice in Service Precautions. INSTALLATION PROCEDURE 1. Install the battery with the positive (+) side up. Use one 3 V CR2032 battery (or the equivalent). 2. Ensure that the seal is in position. Align the 2 halves of the case and snap the two halves together. 3. Resynchronize the transmitter. Page 9803 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 9510 Abbreviations And Meanings - Part 6 Page 6977 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left side instrument panel sound insulator. 2. Disconnect the electrical connector. 3. Remove the remote control door lock receiver from the instrument panel sound insulator by unsnapping it. INSTALLATION PROCEDURE 1. Install the remote control door lock receiver from the instrument panel sound insulator by snapping it. 2. Connect the electrical connector. 3. Install the left side instrument panel sound insulator. 4. Reprogram the transmitters. See: Testing and Inspection/Programming and Relearning 5. Test the operation of the system. Page 587 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Page 1569 Installation Procedure Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. 1. Install the valve pushrods. Important: Be sure that the arrow on the valve rocker arm support is in the up position. 2. Install the valve rocker arm supports. 3. Apply prelude GM P/N 12345501 (Canadian P/N 992704) or equivalent to the following valve rocker arm contact surfaces: ^ Valve pushrod socket (1) ^ Roller pivot (2) ^ Valve stem tip (3) Page 7372 Page 9360 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Diagrams Fuel Tank Pressure (FTP) Sensor Page 3915 Shift Cable: Adjustments Automatic Transmission Range Selector Cable Adjustment 1. Apply the park brake. 2. Place the transmission range selector control lever (column or floor shift) into the NEUTRAL position. 3. Raise and suitably support the vehicle. 4. Remove the positive assurance pin (2) from the bracket. 5. Release the cable lock tab (1). 6. Ensure that the transmission range selector lever is in the NEUTRAL position. Rotate the range select lever fully clockwise then counter clockwise two detents. 7. Pull the cable end completely forward and release it. This allows the adjustment spring to position the cable to its most rearward position. Use care not to pull the cable past the ball stud, this will result in a misadjusted cable. 8. If the adjustment body is not free to move under spring load, a proper adjustment can still be made. Push the adjustment body against the rearward stop. Pull the cable end just far enough forward to install it to the ball stud. Page 8646 Seat Heater: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1923 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ....................................................... ACDelco 41-948 Engine Controls - Lack of Power When Hot PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Lack of Power When Hot Bulletin No.: 05-06-04-077 Date: December 22, 2005 TECHNICAL Subject: Lack of Power (LU3 Engine) at High Ambient Temperatures Only (If Necessary, Reprogram PCM with New Service Calibration) Models: 2003-2005 Chevrolet Astro, Blazer, Express, S-10, Silverado 2003-2005 GMC Jimmy, Safari, Savana, Sierra, Sonoma with 4.3L Vortec(TM) V6 Engine (VIN X - RPO LU3) Condition Some customers may comment that the vehicle may exhibit a lack of power at high ambient temperatures. Cause Engineering has identified a concern with the PCM software. In high ambient temperatures, the engine control management system may falsely retard the timing, causing a noticeable loss of power. Correction Important: Before Reprogramming the PCM, verify the customer concern. Refer to SI Engine Controls and under Diagnostic Information and Procedures. Refer to Lack of Power, Sluggishness, or Sponginess for the cause of the low power condition at high ambient temperatures. If no trouble is found, then reprogram the PCM. Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 12.5, which was broadcast to dealers on 12/11/2005. For the dealerships that use CDs, the CD version will be 1.0 for 2006, which will be mailed 0111212006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7253 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 4730 2. Install the park brake cable in the connector. 3. Install the right rear park brake cable in the equalizer. 4. Install the equalizer spring. 5. Adjust the park brake. 6. Lower the vehicle. Refer to Vehicle Lifting. Page 7640 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7274 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 5931 4. Remove the cotter pin. 5. Remove the tie rod end stud nut. 6. Disconnect the tie rod end from the steering knuckle using J 24319-B. 7. Remove the lower ball joint stud from the steering knuckle using J 23742. 8. Remove the upper ball joint stud from the steering knuckle using J 23742. 9. Raise the upper control arm. Disengage the ball joint stud from the steering knuckle. 10. Remove the steering knuckle from the lower ball joint stud. 10.1. Clean the steering knuckle. 10.2. Inspect the steering knuckle tapered hole. Replace the steering knuckle if this tapered hole is out-of-round, deformed, or damaged. Installation Procedure Page 3024 Steps 9-12 Page 9867 For vehicles repaired under warranty, use the table. Disclaimer Page 5945 Tighten J 29193 or J 29194 to 62 Nm (48 ft. lbs.). 5. Remove J 29193 or J 29194 from the relay rod ball stud. 6. Install the new nut to the relay rod ball stud. Tighten the relay rod ball stud nut to 83 Nm (61 ft. lbs.). 7. Lower the vehicle. Page 7485 Speaker - LR Door (4-Door Utility) Page 2337 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 9215 A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 343 For vehicles repaired under warranty, use the table. Disclaimer Page 2674 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 290 Sunroof / Moonroof Switch: Description and Operation SUNROOF SWITCH The sunroof switch has three positions: - Close - Off, in rest position - Open Pressing the forward portion of the sunroof switch will slide the sunroof window to the close position. Pressing the rearward portion of the sunroof switch will raise the rear edge of the sunroof window and then will move the sunroof window from the close position to the full open position, unless the switch is released. Fuse Block - Underhood Location View Page 9816 Abbreviations And Meanings - Part 2 Page 6855 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Specifications Brake Pedal Assy: Specifications Brake Pedal Pivot Bolt 19 ft. lbs. Page 4156 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Page 56 For vehicles repaired under warranty, use the table. Disclaimer Page 8383 WA813K/89 - WA817K/63 NV 1500 Vehicle Speed Sensor Page 3976 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. OnStar(R) - Incorrect GPS Position Reported During Call Cellular Phone: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 555 Engine Harness Rear (4.3L) Page 5813 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 4209 Removal Procedure 1. Raise and support the vehicle. 2. Remove the rear propeller shaft. 3. Remove the transmission. 4. Remove the clutch actuator bolts. 5. Remove the clutch actuator from the input shaft. 6. Remove the 5 bolts from the front bearing retainer. 7. Use suitable prying tool to remove the input shaft bearing retainer. 8. Remove the input shaft retaining ring. 9. Remove the Input shaft seal from the input shaft bearing retainer. Page 6097 Abbreviations And Meanings - Part 20 Page 9500 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 4172 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Page 7143 Driver Information Center (DIC) C2 (w/ Short Console) Page 7378 Page 4545 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Locations LF Front Fender Area Page 8260 Door Lock Actuator - Front Passenger, RR, LR Page 8483 20. Install the coat hooks and retaining screws. Tighten Tighten the retaining screws to 1.4 N.m (12 lb in). 21. Install the assist handle, the bolts and covers. Tighten Tighten the screws that retain the handle to 9 N.m (80 lb in). 22. Install the upper rear seat belt anchor bolts and covers. When installing the rear seat belt anchors, take care not to pinch the drain hose with the anchor bracket. The hose should sit flat on the back of the headliner. Tighten Tighten the anchor to 80 N.m (59 lb in). 23. Install the upper front seat belt anchor bolts and covers. Tighten Tighten anchor bolts to 70 N.m (52 lb in). 24. Return the rear seats to the upright position. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9341 Page 8663 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 5951 25. Reinstall the pump reservoir cap. Page 5338 C229 (Body Harness To Dome Harness) Page 2278 Transmission Range Switch (W/ A/T) Page 981 Drive Belt Rumbling Diagnosis Step 1 - 8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Page 3743 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Body - Hood Hinge Rattling Noises Hood Hinge: Customer Interest Body - Hood Hinge Rattling Noises Bulletin No.: 01-08-63-001B Date: December 12, 2005 TECHNICAL Subject: Hood Hinge Rattle (Install Spring Washer) Models: 1995-2004 Chevrolet S-10 1995-2005 Chevrolet Blazer 1995-2004 GMC Sonoma 1995-2005 GMC Jimmy 1996-2002 Oldsmobile Bravada (Plant Codes 8 and K) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-08-63-001A (Section 08 - Body and Accessories). Condition Some customers may comment on a rattle coming from either or both front corners of the instrument panel near the hood hinge areas. This noise may often be mistaken for a loose shock absorber. The rattle may be heard when driving over rough roads and is most noticeable when the road surface creates a side-to-side vehicle motion. Cause Excessive clearance at the hood hinge attaching bolt may cause this condition. The excessive clearance allows the hood hinge to make metal contact with the hood hinge bracket, which produces a rattling noise. Correction Important: For additional information, see the Body Front End subsection of the Body and Accessories Section of the appropriate Service Manual. 1. Remove the hood hinge attaching bolt (1). 2. Install a spring washer (2) on the bolt as shown in above illustration. 3. Install the bolt. Tighten Page 4167 The smearing of the metal is due to slippage. Slippage can be caused by the following factors: ^ Poor fits ^ Lubrication ^ Overheating ^ Overloads ^ Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 3135 Steps 1-3 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 1990 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Page 4898 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 4694 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 2720 Steps 1-2 Steps 3-6 IP Fuse Block Details Fuse: Application and ID IP Fuse Block Details Location View Application Table Part 1 Page 5137 Registered And Non-Registered Trademarks - Part 3 Page 3155 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement (Fuel Pipe Repair) Steel fuel lines-These are welded steel tubes, meeting GM specifications 124-M, or the equivalent. The fuel feed line is 9.5 mm (3/8 inches) diameter and the fuel return line is 8 mm (5/16 inches) diameter. Do not use copper or aluminum tubing to replace steel tubing. Those materials do not have satisfactory durability to withstand normal vehicle vibration. Coupled hose-Do not repair the hoses. Replace them only as an assembly. Uncoupled hose-Use only reinforced fuel resistant hose, made of Fluoroelastomer material. Do not use a hose within 100 mm (4 in) of any part of the exhaust system, or within 2154 mm (10 in) of the catalytic converter. The hoses inside diameter must match the outside diameter of the steel tubing. Clamps-These are stainless steel, screw bank-type clamps, #2494772, or equivalent. Steel Fuel Line Repair 1. Cut a piece of fuel hose 100 mm (4 in) longer than the section of line to be removed. If you remove more than 152 mm (6 in), use a combination of steel pipe and hose. The hose length should not be more than 2154 mm (10 in) total. 2. With a tube cutter, cut a section of the pipe to replace. Use the first step on the reamer to form a bead on the ends of the pipe and, also, on the new section of pipe, if used. 3. Slide the hose clamps onto the pipe and push the hose 51 mm (2 in) onto each portion of the fuel pipe. Tighten a clamp on each side of the repair. 4. Secure fuel line to the frame. 5. Check for leaks. Page 3454 ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 3731 7. Carefully lower the transmission to gain access to the cooler line fittings. 8. Remove the TOC lines from the fittings on the transmission. If the vehicle is equipped with 4WD, it may be necessary to disconnect and temporarily relocate the transfer case vent hose to provide access to the fittings. 9. Remove the TOC lines from the vehicle. Installation Procedure 1. Install the TOC lines to the vehicle. 2. Install the TOC lines to the transmission. 3. Install the transfer case vent hose, if equipped. 4. Raise the transmission into position. 5. Install the exhaust crossover pipe and the transmission support assembly 6. Remove the transmission jack. Notice: Refer to Fastener Notice in Service Precautions. 7. For vehicles equipped with a 4.3L engine, install the stud and clip securing the TOC line to the engine. ^ Tighten the stud to 11 Nm (97 inch lbs.). 8. For vehicles equipped with a 2.2L engine, Install the nut securing the TOC lines to the engine. ^ Tighten the nut to 11 Nm (97 inch lbs.). 9. Lower the vehicle. 10. Install the TOC lines to the radiator 11. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 7517 Disclaimer Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 6212 3. Position the rear tie rod in the axle bracket. Notice: Refer to Fastener Notice in Service Precautions. 4. Loosely install the following parts to the frame bracket: ^ The bolt ^ The washers ^ The nut ^ Tighten the rear tie rod to axle bracket nut to 61 Nm (45 ft. lbs.). ^ Tighten the tie rod to the frame bracket nut to 61 Nm (45 ft. lbs.). 5. Remove the rear axle support. 6. Lower the vehicle. Page 592 Camshaft Position (CMP) Sensor Page 5591 Fuse Block - Underhood Connector C1 Part 8 Page 9820 Abbreviations And Meanings - Part 6 Page 5536 Abbreviations And Meanings - Part 15 Page 2142 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 8985 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 1767 24. Remove the seal from the fuel meter body assembly. 25. Discard the seal. Important: Do not immerse the assembled upper intake manifold in cleaning solvent. 26. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent. 27. Inspect the upper intake manifold for the following: ^ Cracks or other damage to the exterior ^ Cracking or damage to the gasket grooves ^ Loose or damaged bolt hole thread inserts ^ Damage to the throttle body mounting surface 28. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold. 29. Remove and discard the seal. Page 5570 Application Table Part 3 Page 8589 INSTALLATION PROCEDURE 1. Install the seat back pad onto the seat back frame. 2. Install the seat back cardboard to the seat by hooking the plastic clips onto the lumbar support. 3. Pull the seat cover over the entire seat back. 4. Engage the J-strip at the base of the seat back. 5. Install the head restraint to the seat back. Seat Back Filler Panel Replacement - Rear SEAT BACK FILLER PANEL REPLACEMENT - REAR REMOVAL PROCEDURE 1. Fold down the rear seat to access the rear seatback filler panel retaining nuts. Page 451 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 2267 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 295 1. Install the sunroof switch to the sunroof console with 6 screws. 2. Connect the electrical connector to the driver information display module. 3. Install the DIC. Page 9686 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 4330 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) Page 6781 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Page 4963 Description and Operation Door Switch: Description and Operation DOOR LATCH, DOOR JAMB SWITCHES The theft deterrent system uses the door latch switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. Page 914 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots » turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Engine Controls - Lack of Power When Hot PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Lack of Power When Hot Bulletin No.: 05-06-04-077 Date: December 22, 2005 TECHNICAL Subject: Lack of Power (LU3 Engine) at High Ambient Temperatures Only (If Necessary, Reprogram PCM with New Service Calibration) Models: 2003-2005 Chevrolet Astro, Blazer, Express, S-10, Silverado 2003-2005 GMC Jimmy, Safari, Savana, Sierra, Sonoma with 4.3L Vortec(TM) V6 Engine (VIN X - RPO LU3) Condition Some customers may comment that the vehicle may exhibit a lack of power at high ambient temperatures. Cause Engineering has identified a concern with the PCM software. In high ambient temperatures, the engine control management system may falsely retard the timing, causing a noticeable loss of power. Correction Important: Before Reprogramming the PCM, verify the customer concern. Refer to SI Engine Controls and under Diagnostic Information and Procedures. Refer to Lack of Power, Sluggishness, or Sponginess for the cause of the low power condition at high ambient temperatures. If no trouble is found, then reprogram the PCM. Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 12.5, which was broadcast to dealers on 12/11/2005. For the dealerships that use CDs, the CD version will be 1.0 for 2006, which will be mailed 0111212006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 8967 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 3282 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Page 4726 1. Install the park brake cable frame retainers. 2. Install the park brake cable in the rear axle housing retainers, if removed. 3. Install the park brake cable in the brake caliper bracket. 4. Install the park brake cable on the park brake actuator. Page 2678 English Prevailing Torque Fastener Minimum Torque Development Part 1 Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Remove the rear bumper impact bar. 2. Remove 4 nuts and 2 stud plate assemblies securing the trailer hitch to each frame rail. 3. Remove the hitch from the frame rails. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the trailer hitch to each frame rail with 4 nuts and 2 stud plate assemblies. Tighten the trailer hitch nuts to 90 N.m (66 lb ft). 2. Install the rear bumper impact bar. Page 1138 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil into a suitable container. 3. For 2WD vehicles, remove the oil filter from the oil filter adapter. 4. For Four-Wheel Drive vehicles, open the access panel in the steering linkage shield. 5. Remove the oil filter from the remote oil filter adapter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Page 1245 Application Table Part 4 Page 1910 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove air cleaner assembly. 3. Remove the spark plug wires from the distributor cap. - Twist each spark plug boot 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 4. Remove the electrical connector from the base of the distributor. 5. Remove the two screws that hold the distributor cap to the housing. 6. Discard the screws. 7. Remove the distributor cap from the housing. 8. Use a grease pencil in order to note the position of the rotor in relation to the distributor housing (1). 9. Mark the distributor housing and the intake manifold with a grease pencil. Page 7598 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 4521 7.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard pad. 7.2. Slowly tighten the C-clamp until the piston is fully seated in the caliper bore. 7.3. Remove the C-clamp from the brake caliper. Notice: Refer to Brake Caliper Notice in Service Precautions. Important: DO NOT disconnect the hydraulic brake flexible hose from the caliper. 8. Remove the brake caliper assembly from the mounting bracket. 9. Support the brake caliper with heavy mechanics wire or equivalent. 10. Remove the inboard brake pad. 11. Remove the retainer spring. 12. Remove the outboard brake pad. 13. Inspect the disc brake mounting and hardware. 14. Inspect the disc brake caliper. 15. Inspect the caliper bolts for corrosion or damage. Do not attempt to polish away any corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper. Page 6096 Abbreviations And Meanings - Part 19 Page 3370 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 7086 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 4465 Brake Bleeding: Service and Repair Pressure Bleeding Procedure Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. Page 4544 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Disconnect the breather tube at the air cleaner outlet duct. 2. Remove the air cleaner outlet duct. 3. Partially drain the cooling system. 4. Remove the radiator inlet hose from the water outlet housing. 5. Remove the PCV valve hose assembly from the valve rocker arm cover. Page 8580 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. 2. Install the electrical connector to the switch. 3. Install the trim panel to the seat with 3 screws. 4. Install the seat to the vehicle. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the seat from the vehicle. Page 2485 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 9428 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 9599 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 9380 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 3977 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. Diagrams Passlock Sensor Page 4204 3. Fill the transmission to the level of the fill plug hole. 4. Apply sealant to the oil fill plug threads. Use sealant GM P/N 12346004 or the equivalent. 5. Using J 36511 install the oil fill plug. ^ Tighten the oil fill plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Page 987 8. Avoid mix-positioning the drive belt by one or more grooves. 9. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed the fix pointer should align within the indentation on the drive belt tensioner. 10. With a used drive belt installed the fix pointer should not align past the index mark. Page 8003 3. Install the lower end of the liftgate struts to the ball joint. Press in to place until fully seated. 4. Remove the support from the liftgate. 5. Close the liftgate. Page 3070 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Page 2388 4. Install the distributor. 5. Connect the negative battery cable. Service and Repair Ground Strap: Service and Repair REMOVAL PROCEDURE Additional ground straps are used to connect the body and the frame to the engine and the transmission. Always connect all ground straps in order to ensure a good ground path to the battery for all electrical components. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the ground strap bolt from the engine. 3. Lower the vehicle. 4. Remove the ground strap bolt from the cowl. 5. Remove the ground strap. INSTALLATION PROCEDURE Page 2293 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 4506 ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Pitting in the caliper bore Assembly Procedure 1. Lubricate the following parts with clean brake fluid. ^ The piston ^ The piston seal ^ The brake caliper bore. Important: Ensure that the piston seal is not twisted in the brake caliper bore groove. 2. Install the piston seal. 3. Install the boot on the piston. 4. Install the piston in the caliper bore. Page 7084 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Locations Instrument Panel Details, RH Page 778 Equivalent - Decimal And Metric Part 1 Page 2895 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 6099 Abbreviations And Meanings - Part 22 Page 9104 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 5246 C203 (Body Harness To IP Harness) Part 1 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4915 Abbreviations And Meanings - Part 15 Page 2175 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 4754 Page 2381 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 3106 Fuel Injector: Service and Repair REMOVAL PROCEDURE Fuel Meter Body Assembly 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Remove the upper intake manifold assembly. 4. Remove the fuel meter body assembly. 5. Remove the injector assembly retainer (11) and the injector retainer lock nuts (10). 6. While pulling the poppet nozzle tube downward, push with a small tip punch down between the injector terminals until the injector is removed. NOTE: Use care in removing the fuel injectors to prevent damage to the electrical connector terminals. The fuel injector is serviced as a complete assembly only. Also since the injectors are electrical components, these injectors should not be immersed in any type of liquid solvent or cleaner as damage may occur. Fuel injector cleaning is not recommended. INSTALLATION PROCEDURE IMPORTANT: Each injector is calibrated for a specific flow rate. Order the correct injector for the application being serviced when replacing the fuel injectors. Page 3601 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) Page 5327 C209 (Dome Harness To Body Harness) Part 3 Page 9501 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 9589 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 5076 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 7098 Conversion English/Metric Part 1 Page 9390 Abbreviations And Meanings - Part 3 Page 9391 Abbreviations And Meanings - Part 4 Page 3343 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 954 Spark Plug: Service and Repair SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 5480 Page 7368 Page 4615 Brake Bleeding: Service and Repair Pressure Bleeding Procedure Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. Page 8086 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 7693 Abbreviations And Meanings - Part 21 Page 8815 Tailgate Latch: Service and Repair Latch Support Replacement - End Gate Window Latch Support Replacement - End Gate Window Removal Procedure 1. Remove the endgate window latch. 2. Disconnect the electrical connectors as needed. 3. Mark the location of the endgate window latch support in order to ensure proper alignment during installation. 4. Remove the bolts that retain the endgate window latch support to the liftgate. 5. Remove the endgate window latch support from the endgate. Installation Procedure 1. Install the endgate window latch support. 2. Align the marks made during disassembly. 3. Connect the electrical connectors as needed. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolts that retain the endgate window latch support to the liftgate. Tighten the bolts to 9 N.m (80 lb in). 5. Connect the electrical connectors as needed. 6. Install the endgate window latch. Page 3474 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Page 4355 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 5683 C223 (IP Harness To Auxiliary Power Tray) (Extended Cab) Page 2758 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 4655 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear brake pads. 4. Remove the anti raffle retainers. 5. Remove the rear brake caliper bracket mounting bolts. 6. Remove the rear brake caliper bracket. Installation Procedure Specifications Idler Arm: Specifications Idler Arm Mounting Bolts and Nuts 79 ft. lbs. Idler Arm to Relay Rod Nut (RWD) 35 ft. lbs. Page 9349 Page 6091 Abbreviations And Meanings - Part 14 Page 492 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 6048 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 9829 Abbreviations And Meanings - Part 15 OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 8845 Truck Bed: Service and Repair Pickup Box Side Panel Replacement - Front Step PICKUP BOX SIDE PANEL REPLACEMENT - FRONT STEP REMOVAL PROCEDURE 1. Use a flat-bladed tool in order to pry the step upward. 2. Remove the step pad from the panel. 3. Remove the rear brace from the step panel. 4. Remove the forward brace from the step panel and the forward support bracket. 5. Remove the screws that secure the step panel to the forward and rear support brackets. Page 4346 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side Service and Repair Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 1833 Use a hammer and the J 46165 Pin Driver to install the dowel pins through the two lower holes in the bracket and into the engine block. Make sure that the bracket is held firmly in place before proceeding. For model years 1996-1998, install a roller-type timing chain set. Install the crankshaft sprocket using the J 5590 Crankshaft Gear Installer. Install the timing chain around the crankshaft sprocket and position the timing chain to the driver's side of the engine. Install the nylon timing chain tensioner guide onto the timing chain tensioner bracket pin and position the top of the guide under the tab at the top of the bracket. Install the camshaft sprocket into the chain and then to the camshaft. Install the bolts finger-tight. Make sure the timing marks are aligned, then tighten the camshaft sprocket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Install the crankshaft reluctor ring. Install the engine front cover and place a washer under the two center cover bolts that extend through the tensioner bracket. These washers are required to maintain the proper crush on the engine front cover seal. Tighten Page 5288 C403 (Body Harness To LH Tail Lamp Harness) (Export) Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 6504 Abbreviations And Meanings - Part 5 Page 264 Seat Adjuster Switch - Driver/Front Passenger (w/ Memory) Part 1 Page 6769 ^ Visually inspect steering shaft for sheared injected plastic (1). If steering shaft shows sheared plastic, a new steering shaft must be installed. ^ Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked in the following manner. Using a dial indicator at the lower end of the steering shaft, have the steering wheel rotated. Runout must not exceed 1.60 mm (.0025 inch). Page 7483 Speaker - LF Door Page 956 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Brake Caliper Replacement - Front (Single Piston) Brake Caliper: Service and Repair Brake Caliper Replacement - Front (Single Piston) Brake Caliper Replacement - Front (Single Piston) Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, using an appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the front caliper piston. Page 527 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 5778 C500 (Body Harness To LF Door Harness) (W/ Power Locks/Windows) Part 2 Page 8108 Console: Service and Repair Console Replacement - Front Floor (Full Length (Envoy) Console Replacement - Front Floor (Full Length (Envoy)) Removal Procedure 1. Remove the front ashtray from console by gently prying out the ashtray with a flat-bladed tool. 2. Carefully lift up on the wood shifter assembly close-out in order to remove the assembly from the console. The closeout panel will need to be rotated to fit over the shift handle. 3. Remove the passenger side toe-panel by gently prying out the panel using a flat-bladed tool. 4. Disconnect the instrument panel to console wiring harness connection. 5. Open the armrest in order to expose and remove the convenience tray from storage compartment. 6. Remove the fasteners (2) that retain the console (1) to the shifter assembly and the vehicle floor. 7. Remove the console from the vehicle by lifting the console over the floor studs. 8. If replacing the center console, remove the compact disc player from the console. Refer to Remote CD Player Replacement in Entertainment. 9. If replacing the center console, remove the amplifier from the console. Refer to Amplifier Replacement in Entertainment. 10. If replacing the center console, remove the rear seat audio control from the console. Refer to Audio Control Replacement - Rear Seat in Entertainment. 11. If replacing the center console, remove and retain the console wiring harness for use on the new console. Installation Procedure Page 8726 Door Lock Cylinder Switch - Driver (Utility W/ Content Theft) Page 7073 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 7115 Abbreviations And Meanings - Part 8 Page 1567 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Mark, sort, and organize all the components for assembly. 2. Remove the valve rocker arms. 3. Remove the valve rocker arm supports. 4. Remove the valve pushrods. Important: Parts that are to be reused must be marked, sorted, and organized for assembly. 5. Mark, sort, and organize the components for assembly. Page 977 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Step 1 - 8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Page 9366 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 207 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and SIR Disabling and Enabling Zone 3. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the floor console, if equipped. 3. Cut an "X" in the carpet over the inflatable restraint sensing and diagnostic module (SDM). 4. Fold the carpet back to expose the SDM. 5. Remove the connector position assurance (CPA) (4) from the SDM harness connector (3). 6. Disconnect the SDM harness connector (3) from the SDM (2). 7. Remove the SDM mounting fasteners (1). 8. Remove the SDM (2) from the vehicle. 9. Repair the fasteners using the following procedure: IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 9.1. Remove the stripped nut and discard the nut. 9.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 9.3. Condition the floor panel attaching surface where the new stud is to be installed. 9.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 9.5. Migweld the stud at the drilled holes from above or below the floor pan (as required). 9.6. Apply body sealer GM P/N 9984248 around any exposed openings. 9.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Page 6423 Instrument Panel, RF Page 9484 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 3812 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 6842 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Page 4284 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 9647 Registered And Non-Registered Trademarks - Part 1 Page 3364 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 5889 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 6275 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 9677 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4865 Specifications Radiator Hose: Specifications Radiator Inlet Hose Support Bracket Nut to Exhaust Manifold Stud ....................................................................................................... 36 Nm (27 ft. lbs.) Page 2573 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 8549 Seat Lumbar Motor - Driver Page 2159 4. Disconnect the PCM electrical connectors. Installation Procedure 1. Remove the replacement PCM from the packaging. 2. Check the service number in order to make sure the service number is the same number as the defective PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM electrical connectors screws to 8 N.m (71 lb in). Service and Repair Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside Removal Procedure 1. Close the window. 2. Remove the door trim panel. 3. Peel back the corner of the water deflector in order to expose the door handle screw access hole. 4. Remove the outside door handle screw access hole plug. 5. Remove the outside door handle rod from the handle. 6. Remove the screws that retain the outside door handle to the door panel. 7. Remove the outside door handle from the door. Installation Procedure 1. Install the outside door handle to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the outside door handle to the door. Tighten the screws to 4 N.m (35 lb in). 3. Install the outside door handle rod to the handle. 4. Install the outside door handle screw access hole plug. 5. Return the water deflector corner to the original position. 6. Install the door trim panel. Page 7250 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 7069 Page 5712 C101 (Body Harness To Engine Harness) Part 2 Page 1153 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. See: Heating and Air Conditioning/Specifications/Capacity Specifications Page 8787 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement With RPO Code Zrx/Extreme W/CF5 SUNROOF SWITCH REPLACEMENT (ZRX/EXTREME W/CF5) REMOVAL PROCEDURE 1. With a medium flat-bladed tool, remove the motor/actuator service cover. 2. Remover the motor/actuator trim cover screw (2). 3. Lower the trim cover (5). 4. Remove the switch (4) from the cover. 5. Disconnect the motor/actuator electrical connector (3). 6. Remove the ground screw (3) and ground wire (2) from the header in behind the motor/actuator. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Wheel Speed Sensor Replacement (RWD Pickup) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor cable electrical connector (2). 6. Remove 13 mm bolt and nut fastening the wheel speed sensor harness clip to the front side of the upper control arm. 7. Remove clips from the wheel speed sensor wire. Save the clips for the sensor wire. 8. Remove two 13 mm wheel speed sensor mounting bolts (7). 9. Remove two 11 mm splash shield mounting bolts. 10. Remove wheel speed sensor and splash shield assembly (6). 11. Remove splash shield gasket. 12. Clean gasket and knuckle surfaces thoroughly with a dry cloth. Installation Procedure 1. Install splash shield gasket. 2. Install wheel speed sensor and splash shield assembly (6). Notice: Refer to Fastener Notice in Service Precautions. 3. Install two 11 mm splash shield mounting bolts. ^ Tighten the splash shield mounting bolts to 16 Nm (12 ft. lbs.). ^ Tighten the speed sensor mounting bolts (7) to 26 Nm (119 ft. lbs.). 4. Install harness clips to the wheel speed sensor wire. Page 6808 1.2. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 o'clock position. 2. If centering is required, follow the instructions on the notice (1) of the coil assembly. Refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. If the SIR coil does not come with a centering tab, you must center the SIR coil. 3. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam assembly (2). 4. Slide the new SIR coil (4) onto the steering shaft assembly (2). Page 348 Brake Caliper Replacement - Front (Single Piston) Brake Caliper: Service and Repair Brake Caliper Replacement - Front (Single Piston) Brake Caliper Replacement - Front (Single Piston) Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, using an appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the front caliper piston. O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement O-RING REPLACEMENT REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 5. Cap or tape the A/C refrigerant components. IMPORTANT:Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT:DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. IMPORTANT:DO NOT reuse O-ring seals. Page 5203 Application Table Part 2 Page 3672 For vehicles repaired under warranty, use the table. Disclaimer Page 8023 Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water in order to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Page 2261 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 1991 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 114 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 1227 Fuse Block - Underhood Connector C4 Part 3 Page 5648 C106 (Forward Lamp Harness To Body Harness) Part 1 Page 4350 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 6406 Wheel Nut Torque Sequence Page 5273 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 1 Page 2602 4. Disconnect the PCM electrical connectors. Installation Procedure 1. Remove the replacement PCM from the packaging. 2. Check the service number in order to make sure the service number is the same number as the defective PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM electrical connectors screws to 8 N.m (71 lb in). Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 6043 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 2150 Powertrain Control Module (PCM) Connector C2 Part 2 Page 8200 1. Use the J 38778 in order to remove the rear header garnish molding. Insert the J 38778 and work along the front edge of the trim panel from one end to the other. 2. Remove the cargo lamp from the roof rear header garnish molding. Installation Procedure 1. Install the cargo lamp from the roof to the rear header garnish molding. 2. install the roof rear header garnish molding to the vehicle. Garnish Molding Replacement - Side Door Lock Pillar (CF5) Garnish Molding Replacement - Side Door Lock Pillar (CF5) Removal Procedure 1. Remove the front and rear door sill trim plates. 2. Remove the upper and lower front seat belt anchor bolts. 3. Remove the front side door lock pillar garnish molding from the vehicle. Feed the seat belt through the garnish molding. Installation Procedure 1. Install the front side door lock pillar garnish molding to the vehicle. Feed the seat belt through the garnish molding. Notice: Refer to Fastener Notice in Service Precautions. Page 5967 8. Clean the magnet (3). 9. Inspect the Welch plug in the power steering pump housing (2). Do not remove. If the Welch plug is deformed or dislodged, replace the power steering pump housing (2). Assembly Procedure Important: Use new O-ring seals when assembling the power steering pump assembly. 1. Lubricate the O-ring seals (1) (4) (5) with power steering fluid. 2. Install the O-ring seals (1) (4) (5) to the pump housing assembly. 3. Install the magnet (3) to the pump housing assembly (2). 4. Connect the reservoir assembly (1) to the pump housing assembly (2). 5. Install the O-ring seal. Notice: Refer to Fastener Notice in Service Precautions. Page 5499 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4141 9. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 10. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block (2). 11. Push the flange of the axle shaft inward towards the differential assembly. 12. Remove the axle shaft lock from the button end of the axle shaft. Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult. 13. Remove the axle shaft from the housing. Installation Procedure Important: Carefully insert the axle shaft in order to not damage the seal. 1. Install the axle shaft into the rear axle housing. 2. Slide the axle shaft into the differential assembly allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the axle shaft lock on the button end of the axle shaft. Page 8666 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 8189 Trim Panel: Service and Repair Garnish Molding Replacement - Side Door Lock Pillar (CF5) Garnish Molding Replacement - Side Door Lock Pillar (CF5) Removal Procedure 1. Remove the front and rear door sill trim plates. 2. Remove the upper and lower front seat belt anchor bolts. 3. Remove the front side door lock pillar garnish molding from the vehicle. Feed the seat belt through the garnish molding. Installation Procedure 1. Install the front side door lock pillar garnish molding to the vehicle. Feed the seat belt through the garnish molding. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper and the lower front seat belt anchor bolts. Tighten the screws to 70 N.m (52 lb ft). 3. Install the front and the rear door sill trim plates. Page 9088 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1724 2. Apply a 5 mm (0.197 inch) wide and 25 mm (1.0 inch) long bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces. Important: Always install a NEW oil pan gasket. The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. 3. Install the NEW oil pan gasket into the groove in the oil pan. Important: The oil pan alignment must always be flush or forward no more than 0.3 mm (0.011 inch) from the rear face of the engine block. 4. install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing. 5. Slide the oil pan back against a suitable straight edge. Page 6362 Wheels: Service and Repair Steel Wheel Repair Steel Wheel Repair Description Notice: ^ Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. ^ The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Page 9795 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 9237 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 7674 Abbreviations And Meanings - Part 2 EVAP Canister Vent Valve Replacement (2-Door) Canister Vent Valve: Service and Repair EVAP Canister Vent Valve Replacement (2-Door) REMOVAL PROCEDURE 1. Raise the vehicle. 2. Lower the spare tire, underbody mounted spare tire only. 3. Remove the shield (2) from the fuel tank shield (3). 4. Disconnect the vent valve electrical connector. 5. Disconnect the vent hose (3). 6. Bend back the tang on the bracket. Page 599 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 5507 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 2105 1. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold. 2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets, 3. Install the exhaust manifold. 4. Install the spark plug wire shields. 5. If reusing the fasteners, apply threadlock GM P/N 112345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the exhaust manifold bolts. 6.1. Tighten the exhaust manifold bolts on the first pass to 15 Nm (11 ft. lbs.). 6.2. Tighten the exhaust manifold bolts on the final pass to 30 Nm (22 ft. lbs.). 7. Install the spark plug wires to the spark plug wire retainers. 8. Install the spark plug wires onto the spark plugs. 9. Raise the vehicle. Refer to Vehicle Lifting. 10. Connect the exhaust pipe to the exhaust manifold. 11. Lower the vehicle. 12. Install the boll for the oil level indicator tube. ^ Tighten the oil level indicator tube bolt to 12 Nm (106 inch lbs.). Page 3834 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 9508 Abbreviations And Meanings - Part 4 Page 7287 Abbreviations And Meanings - Part 13 Page 5445 For vehicles repaired under warranty, use the table. Disclaimer Page 7074 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 830 Window Switch - RR Page 7297 Abbreviations And Meanings - Part 23 Page 901 Disclaimer Page 8893 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Remove the side rear door trim panel. 2. Remove the staples that secure the sealing strip to the trim panel. 3. Remove the sealing strip. Installation Procedure 1. Position the sealing strip on the trim panel. 2. Install the sealing strip to the trim panel using the original staples or a heavy-duty staple gun. 3. Install the side rear door trim panel. Page 5458 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 6621 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Locations Blower Motor Relay: Locations Body Wiring To Blower Motor And Resistor (With RPO Code C42) Page 8757 Seat Lumbar Switch - Driver Part 1 Page 3862 Shift Interlock Solenoid: Diagrams W/Floor Shift W/ Column Shift Page 1192 Application Table Part 2 Page 4869 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4931 Registered And Non-Registered Trademarks - Part 4 Page 3511 2. Install the following parts: 2.1. The O-ring on the vehicle speed sensor assembly. 2.2. The vehicle speed sensor assembly. 2.3. Tighten Tighten the bolt to 16 Nm (12 ft. lbs.). 3. Install the electrical connector to the vehicle speed sensor. 4. Lower the vehicle. Page 1762 Intake Manifold: Service and Repair Upper Intake Manifold Replacement Intake Manifold Replacement - Upper Removal Procedure Important: The upper intake does not have to be removed to remove the lower intake manifold. 1. Disconnect the breather tube at the air cleaner outlet duct. 2. Remove the air cleaner outlet duct retaining wingnut. 3. Disconnect the IAT sensor harness connector. Page 6124 5. Remove the outer tie rod ball stud from the steering knuckle using J 24319-B. 6. Remove the inner tie rod ball stud from the relay rod using J 6627-A. 7. Perform the following steps in order to remove the tie rod ends from the adjuster tube: 7.1. Loosen the clamp bolts. 7.2. Unscrew the assemblies. 8. Inspect for the following possible conditions: ^ The tie rod ends for damage ^ The tie rod end seals for excessive wear ^ The tie rod threads for damage ^ The tie rod ends for damage ^ The ball stud threads for damage ^ The adjuster tube for bending ^ The adjuster tube for damaged threads 9. Clean the following components: ^ The ball stud threads ^ The ball stud nut ^ The tapered surfaces Installation Procedure Important: If the tie rod ends were removed, lubricate the tie rod ends with chassis lubricant. Page 5614 Application Table Part 2 Page 8488 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Rear SUNROOF DRAIN HOSE REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the headliner. 2. Disconnect the rear drain hose from the drain exit located at the rear of the sunroof on either side. 3. Remove the rosebud clips securing the drain hose to the vehicle. 4. Remove the drain hose. INSTALLATION PROCEDURE Page 9770 Page 1772 ^ The fuel meter body assembly (1) ^ The manifold absolute pressure (MAP) sensor (3) ^ The EVAP canister purge solenoid valve (2) 22. Connect the following electrical connectors: ^ The A/C compressor clutch (1) ^ The A/C compressor cutoff switch (5), if equipped ^ The Throttle Position (TP) sensor (2) ^ The Idle Air Control (IAC) motor (3) 23. Connect the vacuum hose from the vacuum tank to the intake manifold. 24. Install the power brake booster vacuum hose to the intake manifold. 25. Install the cruise control cable, if equipped to the throttle shaft and the bracket. 26. Install the accelerator cable onto the throttle body. Page 8927 Tighten Tighten the cruise control module nuts to 9.0 N.m (6.6 lb ft). 4. Connect the electrical connector. 5. Install the cruise control cable. 6. Connect the battery negative cable. 7. Test the systems operation. Page 5524 Abbreviations And Meanings - Part 3 Page 2866 Engine Generator And Starter Locations Electronic Components Page 6572 8. With the compressor mounted on the J 34992, position the pulley rotor (1) and the bearing assembly on the front head. 9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 10. Position the J 8433-1 on the J 33023-A. 11. Assemble the 2 through bolts and the washers through the puller bar slots. 12. Thread the through bolts into the J 34992. Ensure that the thread of the through bolts engage the full thickness of the J 34992. 13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps: 13.1. Loosen the J 8433-3. 13.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. 14. Use the J 6083 in order to install the following components: - The pulley rotor (1) - The retaining ring (2) 15. Install the clutch plate and hub assembly. V7 - Direct Mount CLUTCH ROTOR AND/OR BEARING INSTALL (V7 - DIRECT MOUNT) TOOLS REQUIRED - J 33013-B Hub and Drive Plate Remover/Installer - J 33017 Pulley and Bearing Installer - J 41790 Compressor Holding Fixture Page 5520 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 9544 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - HEATED GLASS ELEMENT IMPORTANT: For the inside rearview mirror with the automatic day-night feature or the rear window defogger (w/o C68), review the system operation in order to familiarize yourself with the system functions. Refer to the following: - Automatic Day-Night Mirror Description and Operation - Rear Window Defogger Description and Operation For the rear window defogger (w/ C68) system, perform the following steps before using the symptom tables. 1. Perform Diagnostic System Check - Defogger before using the symptom tables in order to verify that all of the following conditions are true: - No DTCs are set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Defogger 2. Review the rear window defogger system operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the rear window defogger or the automatic day-night feature of the inside rearview mirror. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Bad electrical connections or bad wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list: Defogger Inoperative - Rear Window - Defogger Grid Lines Diagnosis - Mirrors - Automatic Day-Night Inoperative Automatic Day/Night Mirror Inoperative - Mirrors Steps 1-2 Page 8714 Heated Seats Diagram 2 Page 9977 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 2936 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 807 Abbreviations And Meanings - Part 16 Page 5666 C203 (Body Harness To IP Harness) Part 7 Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch - Driver (Utility, Crew Cab W/ RKE) Page 7915 Page 1376 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Page 6546 5. Install the stud to the dash panel, if necessary. 6. Install the resistor harness. 7. Install the A/C relay bracket into the body. Page 4933 Generator Page 8326 WA379E/86 - WA382E/11 Page 831 Power Window Switch: Service and Repair POWER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power window switch from the trim panel by using a flat-bladed tool in order to pry upward on the leading edge. 2. Disconnect the electrical connector from the switch. Use a small screwdriver in order to press in the retainer springs. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 5124 Abbreviations And Meanings - Part 17 Page 3920 15. Remove the cable end (1) from the steering column ball stud. 16. Remove the retainer (2) securing the cable to the steering column bracket. 17. Depress the tangs and remove the cable from the steering column bracket. 18. Remove the cable from the retainer (1) located next to the accelerator pedal. 19. Remove the sound deadening material from the floor panel that covers the cable. 20. Pull the cable up through the opening in the floor panel and remove the cable from the vehicle. Installation Procedure 1. Install the cable through the opening in the floor panel. 2. Install the grommet to the floor panel. 3. Install the sound deadening material that covers the cable. 4. Install the cable to the retainer (1) located next to the accelerator pedal. Page 5080 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 5260 C209 (Dome Harness To Body Harness) Part 3 Page 3461 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Locations Instrument Panel Details, RH Page 7255 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Locations Endgate Harness Routing View Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 6380 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Distributor Ignition (DI) System Description Engine Control Module: Description and Operation Distributor Ignition (DI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: The Throttle Position (TP) sensor - The Engine Coolant Temperature (ECT) sensor - The Mass Airflow (MAF) sensor - The Intake Air Temperature (IAT) sensor - The Vehicle Speed Sensor (VSS) - The transmission gear position or range information sensors - The engine Knock Sensors (KS) Page 6508 Abbreviations And Meanings - Part 9 Page 9492 Equivalent - Decimal And Metric Part 2 Page 9800 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 5553 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 5723 C117 (Engine Harness To AIR Harness, w/ California Emissions) Page 4901 Abbreviations And Meanings - Part 1 Page 5382 Splice Pack SP203 Part 2 Page 7141 Driver Information Center (DIC) C1 (w/ Trip Computer) Part 2 Page 6063 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 4914 Abbreviations And Meanings - Part 14 Page 8983 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 5535 Abbreviations And Meanings - Part 14 Page 4247 1. Install the transmission mount to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to the transmission mounting bolts. ^ For vehicles equipped with 2.2L, tighten the bolts to 45 Nm (33 ft. lbs.). ^ For vehicles equipped with 4.3L, tighten the bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut. ^ Tighten the nut to 57 Nm (42 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Page 598 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 4057 Left Side Control Valve Body Assembly Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 2949 Engine Harness Rear (4.3L) Page 4571 3. Remove the hub and bearing assembly. 4. Remove the splash shield. Installation Procedure 1. Install the splash shield. 2. Install the hub and bearing assembly. 3. Install the tire and wheel assembly. 4. Lower the vehicle. 5. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 6. Slowly release the brake pedal. 7. Wait 15 seconds, then repeat steps 5-6 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Backing Plate Replacement - Rear Disc Brake Backing Plate Replacement - Rear Removal Procedure 1. Release the park brake, if applied. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. Notice: Refer to Brake Caliper Notice in Service Precautions. Page 204 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Page 649 4. Install the distributor. 5. Connect the negative battery cable. Page 4863 Page 279 Liftglass/Endgate Lock Cylinder Switch Page 9082 Page 7628 Page 860 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is louver than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height. The front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at thigh speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Page 7707 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Page 1583 3. Install the valve rocker arm cover onto the cylinder head. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve rocker arm cover bolts. Tighten the valve rocker arm cover bolts to 12 Nm (106 inch lbs.). 5. Position the engine wiring harness. 6. Connect the CKP sensor electrical connector (2). 7. Install the engine wiring harness and the bolt (3) to the generator mounting bracket. Tighten the engine wiring harness bolt to 25 Nm (18 ft. lbs.). 8. Position the heater hoses. Page 3137 Step 8 Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Cooling System - Rubbing/Scraping Noise on Turns Fan Blade: Customer Interest Cooling System - Rubbing/Scraping Noise on Turns Bulletin No.: 03-06-02-006 Date: July 30, 2003 TECHNICAL Subject: Rubbing/Scraping Noise During Turns (Reposition Cooling Fan Shroud) Models: 2003 Chevrolet Blazer, S-10 2003 GMC Jimmy, Sonoma with 4.3L V6 Engine (VIN X RPO LU3) Condition Some customers may comment on a rubbing/scraping noise during turns, more commonly left turns. Cause This sound resembles a tire rubbing against the inner tender, but may actually be the engine cooling fan contacting the fan shroud. Correction 1. Loosen the three upper cooling fan shroud bolts. 2. Reposition the shroud so there is a equal amount of clearance all the way around the fan and the shroud. 3. Tighten the upper cooling tan shroud bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8147 1. Install the rubber pad. 2. Slide the cupholder into the bracket. 3. Snap the cupholder into place. Page 9151 Registered And Non-Registered Trademarks - Part 2 Sunroof Drain Hose Replacement - Front Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Front SUNROOF DRAIN HOSE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the sunroof drain hose from the spigot at the front corner of the sunroof. 3. Unwrap the tape in order to remove the hose. IMPORTANT: The left front sunroof drain hose is a part of the dome lamp wiring harness. Page 6778 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 9663 Page 3415 Engine, LR Page 3189 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the air cleaner outlet resonator. 3. Disconnect the idle air control (IAC) valve harness connector. 4. Remove the IAC valve mounting screws. 5. Remove the IAC valve and O-ring from the throttle body assembly. CLEANING AND INSPECTION PROCEDURE 1. Clean the IAC valve O-ring sealing surface, pintle valve seat, and air passage. - Remove excess carbon deposits with a small amount of carburetor cleaner on a parts cleaning brush. Follow any instructions on the cleaner Page 8126 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. Page 5615 Application Table Part 3 Page 9249 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Service and Repair Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT TOOLS REQUIRED - J 26549-E Orifice Tube Remover and Installer or Equivalent - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube from the evaporator (1). 3. Remove the O-ring seal and discard. 4. Use the J 26549-E in order to remove the expansion (orifice) tube (2). 5. If you have difficulty removing a restricted or plugged expansion (orifice) tube, use the following procedure: 5.1. Remove as much of any impacted residue as possible. 5.2. Carefully apply heat with a heat gun (hair dryer, epoxy dryer, or equivalent) approximately 7 mm (0.25 in) from the dimples on the inlet pipe. NOTE: If the system has a pressure switch near the expansion (orifice) tube location, it should be removed prior to heating the pipe to avoid damage to switch. IMPORTANT:DO NOT overheat the pipe. 5.3. While applying heat, use the J 26549-E or equivalent in order to grip the expansion (orifice) tube. 5.4. Use a turning motion along with a push-pull motion in order to loosen the impacted expansion (orifice) tube. Remove the expansion (orifice) tube. INSTALLATION PROCEDURE 1. Use the J 26549-E in order to install the expansion (orifice) tube (2). Page 2368 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 654 Impact Sensor: Diagrams Inflatable Restraint Front End Discriminating Sensor - Left Page 8237 Disclaimer Page 8686 Abbreviations And Meanings - Part 6 Page 3953 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 8177 Sun Visor: Removal and Replacement Sunshade Replacement Removal Procedure 1. Remove the screws that retain the sunshade to the roof. 2. Disconnect the electrical connections, if equipped. 3. Remove the screw that retains the sunshade retainer to the roof. 4. Remove the sunshade from the vehicle. Installation Procedure 1. Install the sunshade to the roof. Diagrams Remote Control Door Lock Receiver (RCDLR) Page 4899 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 5730 C203 (Body Harness To IP Harness) Part 4 Page 1562 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 8785 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement With RPO Code CF5 SUNROOF SWITCH REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the driver information console (DIC). 2. Disconnect the electrical connector from the driver information display module. 3. Remove 6 screws securing the sunroof switch assembly to the DIC. 4. Remove the sunroof switch assembly from the DIC. INSTALLATION PROCEDURE Service and Repair Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 5189 Fuse Block - Underhood Connector C5 Page 5082 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Locations Vehicle Speed Sensor: Locations Manual Transmission, LH Page 2302 Park Neutral Position (PNP) Switch Page 1721 8. Tighten the oil pan bolts and nuts in sequence. ^ Tighten the oil pan bolts to 25 Nm (18 ft. lbs.). 9. Measure the clearance between the 3 oil pan-to-transmission housing measurement points in order to ensure proper alignment. 10. Install a NEW oil pan drain plug seal (0-ring) onto the oil pan drain plug. 11. Install the oil pan drain plug into the oil pan. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). Important: The low oil level sensor is not reusable. Use a NEW low oil sensor. 12. Install the NEW engine oil level sensor (if applicable). ^ Tighten the engine oil level sensor to 13 Nm (115 inch lbs.). 13. Install the engine. 14. Fill the engine with oil. Page 6282 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 6370 The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears Page 8814 Tailgate Latch: Service and Repair Latch Replacement - End Gate Window Latch Replacement - End Gate Window Removal Procedure 1. Remove the endgate cover. 2. Mark the location of the endgate window latch in order to ensure proper alignment at installation. 3. Disconnect the electrical connectors, as needed. 4. Remove the nuts that retain the endgate window latch to the endgate window latch support. 5. Remove the endgate window latch from the endgate. Installation Procedure 1. Install the endgate window latch. Ensure that the latch is properly aligned with the marks made during disassembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the endgate window latch to the endgate window latch support. Tighten the nuts to 10 N.m (88 lb in). 3. Connect the electrical connectors, as needed. 4. Install the endgate cover. Page 3244 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Page 4524 6.2. Slowly tighten the C-clamp until the piston is fully seated in the caliper bore. 6.3. Remove the C-clamp from the brake caliper. Important: DO NOT disconnect the brake hose from the brake caliper. 7. Remove the brake caliper assembly from the mounting bracket. Notice: Refer to Brake Caliper Notice in Service Precautions. 8. Support the brake caliper with heavy mechanics wire or equivalent. 9. Remove the inboard brake pad. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 5495 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 4867 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 3416 Engine Harness Rear (4.3L) Page 7429 Page 1488 5. Use the J 3049-A in order to remove the stuck valve lifters. 6. Use a cleaning solvent and a shop towel to clean any varnish from the valve lifter bores. 7. Inspect the valve lifter bores for excessive wear or scoring. Replace the engine block if there is excessive wear or deep scoring. 8. Inspect the camshaft for wear or damage. If the wear is questionable remove the camshaft and inspect. Important: Components that are to be reused must be marked, sorted, and organized for assembly. 9. Mark, sort, and organize the components for assembly. 10. Clean the components in cleaning solvent. 11. Dry the components with compressed air. 12. Inspect the valve lifter pushrod guides for excessive wear. 13. inspect the valve lifter pushrod guides for cracks or damage. Page 1749 5. Remove the accelerator cable from the accelerator control cable bracket. 6. Disconnect the cruise control cable, if equipped, from the throttle shaft and the accelerator cable bracket. 7. Disconnect the vacuum hose from the intake manifold, if equipped with A/C. 8. Disconnect the power brake booster vacuum hose 9. Drain the cooling system. 10. Remove the radiator inlet hose at the water outlet. 11. Remove the heater hose from the intake manifold. 12. Remove the water pump inlet hose from the intake manifold. Page 6651 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module (BCM) C1 Part 1 Service and Repair Front Door Hinge: Service and Repair Hinge Roller Pin Replacement - Door Tools Required J 36604 Door Hinge Spring Compressor Removal Procedure Caution: Before removing the spring, cover the spring with a towel to prevent the spring from flying and possibly causing damage or personal injury. 1. Remove the door hinge spring using the J 36604. 2. Remove the C-clips that retain the door hinge roller pins. 3. Support the door in the open position. 4. Remove the door hinge roller pins from the vehicle. Use a soft-faced hammer and locking pliers in order to remove the hinge pins. 5. Position the door away from the hinge. Remove and discard the old bushings. Installation Procedure 1. Install the new bushings and position the door on the hinges. 2. Install the door hinge roller pins to the vehicle. Page 7112 Abbreviations And Meanings - Part 5 Electronic Brake Control Module (EBCM) Connector C1 Page 6598 NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the bolts to ....1.9 N.m (17 lb in). 3. Install the evaporator tube to the condenser. 4. Install the compressor hose assembly to the condenser. 5. Tighten the compressor hose nut. Tighten Tighten the nut to ...............28 N.m (21 lb ft). 6. Install the radiator. 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 4852 Page 3402 Crankshaft Position (CKP) Sensor Automatic Trans Range Selector Cable Replace-Column Shift Shift Cable: Service and Repair Automatic Trans Range Selector Cable Replace-Column Shift Automatic Transmission Range Selector Cable Replacement (Column Shift) Removal Procedure 1. Apply the park brake. 2. Position the steering column shift lever in the NEUTRAL position. 3. Raise the vehicle. 4. Disconnect the range selector cable (2) from the range selector lever ball stud (1). 5. Remove the positive assurance pin (2) from the bracket. 6. Remove the retainer (1) from the range selector cable and transmission bracket. 7. Depress the tangs and remove the range selector cable from the bracket. 8. Remove the transfer case shield, if equipped. Page 1021 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Note the position of the fuel strainer (2) on the fuel sender. 7. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand. 8. Pull the strainer off the fuel sender. Discard the strainer after inspection. 9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. INSTALLATION PROCEDURE 1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated. 2. Install the fuel sender assembly. 3. Install the fuel tank. 4. Refill the fuel tank. Page 7088 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 1686 2. For a RWD vehicle, install the oil filter to the oil filter adapter. 3. For Four-Wheel Drive vehicles, install the oil filter to the remote oil filter adapter. 4. Tighten the oil filter following the instructions on the filter. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan drain plug into the oil pan. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the crankcase with the proper capacity and quality of engine oil. 8. Operate the engine and check for leaks and oil pressure. 9. For a Four-Wheel Drive vehicles, close the access panel in the steering linkage shield. Page 7632 Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 6289 Disclaimer Page 924 For vehicles repaired under warranty, use the table. Disclaimer Page 6912 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove off road skid plate, if equipped. 3. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 4. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. 5. Drill out the mounting rivets. 6. Remove the inflatable restraint front end discriminating sensor from the vehicle. Page 815 Abbreviations And Meanings - Part 24 Page 627 Specifications Crankshaft: Specifications Crankshaft Crankshaft End Play ................................................................................................................................................ 0.050 0.20 mm (0.002 - 0.008 inch) Crankshaft Main Bearing Clearance #1 - Production ............................................................................................ 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Crankshaft Main Bearing Clearance #2, #3, and #4 - Production ..................................................................... 0.028 - 0.058 mm (0.0011 - 0.0023 inch) Crankshaft Main Bearing Clearance #1 - Service ............................................................................................. 0.0254 - 0.05 mm (0.0010 - 0.0020 inch) Crankshaft Main Bearing Clearance #2, #3, and #4 Service ........................................................................... 0.025 - 0.063 mm (0.0010 - 0.0025 inch) Crankshaft Main Journal Diameter #1 .......................................................................................................... 62.199 - 62.217 mm (2.4488 2.4495 inch) Crankshaft Main Journal Diameter #2 and #3 ............................................................................................... 62.191 - 62.215 mm (2.4485 - 2.4494 inch) Crankshaft Main Journal Diameter #4 .......................................................................................................... 62.179 - 62.203 mm (2.4480 2.4489 inch) Crankshaft Main Journal Out-of-Round - Production .................................................................................................................. 0.005 mm (0.0002 inch) Crankshaft Main Journal Out-of-Round - Service ....................................................................................................................... 0.025 mm (0.0010 inch) Crankshaft Main Journal Taper ................................................................................................................................................... 0.007 mm (0.0003 inch) Crankshaft Pulley Bolt ......................................................................................................................... ..................................................... 58 Nm (43 ft. lbs.) Crankshaft Balancer Bolt ................................. ......................................................................................................................................... 95 Nm (70 ft. lbs.) Crankshaft Balancer Remover/Installer Bolt ............................................................................................................................................ 25 Nm (18 ft. lbs.) Crankshaft Bearing Cap Bolt - Preferred Method First Pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 73 degrees Crankshaft Bearing Cap Bolt - Optional Strategy ................................................................................................................................... 105 Nm (77 ft. lbs.) Crankshaft Main Bearing Bore Out-of-Round ................................................................................................................................... 0.050 mm (0.002 inch) Page 9061 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 6558 2. Install the molding to the quarter panel rear window (4-Door only). 3. Install the molding fasteners to the quarter panel rear window (4-Door only). 4. Install the body side stationary window (2-Door only). Locations Blower Motor Relay: Locations Body Wiring To Blower Motor And Resistor (With RPO Code C42) Locations Left Hand Side Of Instrument Panel Page 6604 HVAC Control Assembly C2 Page 1059 INSTALLATION PROCEDURE 1. Insert the J 44551 -6 sizing tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the suction hose. 3. Install the J 44551 -3 mandrel (1) to J 44551 -5. 4. Install the J 44551 -5 suction screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551 -5. The suction screen is fully installed when the screen is flush with the end of the suction hose. IMPORTANT:Correct placement of J 44551 -5 is critical. 6. Remove the J 44551 -5 suction screen tool from the suction hose. Service and Repair Tailgate Hinge: Service and Repair Torque Rod Replacement - End Gate Removal Procedure 1. Remove the bolts that retain the endgate torque rod bracket to the vehicle body. With the endgate in the closed position, the bolts are accessible underneath the vehicle between the bumper and the vehicle body. 2. Open the endgate. 3. Remove the bolts that retain the endgate torque rod insulator to the endgate. 4. Remove the endgate torque rod. 5. Remove the endgate bracket. 6. Remove the insulator from the vehicle. Installation Procedure 1. Install the endgate torque rod. 2. Install the endgate bracket. 3. Install the insulator to the vehicle. Page 500 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 3760 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Powertrain Control Module (PCM) Connector C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C1 Powertrain Control Module (PCM) Connector C1 Part 1 Page 2724 Steps 15-18 Page 265 Seat Adjuster Switch - Driver/Front Passenger (w/ Memory) Part 2 Page 790 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 5870 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 9264 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting bolt. Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). Page 5667 C203 (Body Harness To IP Harness) Part 8 Page 2460 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the number 1 mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove the distributor and reinstall the distributor. 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the distributor clamp bolt to 25 N.m (18 lb ft). Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Remove the body side stationary window (2-Door only). 2. Remove the molding from the quarter panel rear window (4-Door only). 3. Remove the pressure relief ventilation valve using a flat-bladed tool in order to release the retainers. Installation Procedure 1. Install the pressure relief ventilation valve assembly pressing into place until firmly seated. Page 6751 A/C Accumulator Page 179 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C2 Powertrain Control Module (PCM) Connector C2 Part 1 Page 4967 Page 4492 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front (Single Piston) Brake Caliper Overhaul - Front (Single A Piston) Tools Required ^ J26267 Piston Seal Installer Disassembly Procedure 1. Drain all of the brake fluid from the caliper. 2. Install a piece of wood or shop towels between the caliper and the piston. 3. Cover the brake caliper with a shop rag. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 4. Apply only enough compressed air to the brake caliper to remove the piston. 5. Remove the shop rag cover from the brake caliper. 6. Remove the piece of wood or shop towels from the brake caliper. 7. Remove the boot from the front brake caliper. Important: When removing the, front brake caliper piston seal, use a non metallic tool. Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 7673 Abbreviations And Meanings - Part 1 Page 3764 10. Remove the bolt securing the filler tube to the torque converter housing. 11. Remove the filler tube and seal from the vehicle. Installation Procedure 1. Install a new seal into the transmission case. 2. Lubricate the seal with transmission fluid and install the filler tube into the seal. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt securing the filler tube to the transmission torque converter housing. ^ Tighten the bolt to 47 Nm (35 ft. lbs.). 4. Raise the transmission. 5. Install the transmission support. 6. Remove the transmission jack. 7. If the vehicle is equipped with a 2.2L engine, proceed to step 9. 8. Install the rear output shaft. 9. Install the exhaust manifold pipe. 10. Lower the vehicle. Page 9745 Door Lock And Window Switch - Driver C2 Page 9133 Abbreviations And Meanings - Part 11 Page 5711 C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 2 C101 (Body Harness To Engine Harness) Part 1 OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 8441 Sunroof / Moonroof Motor: Description and Operation SUNROOF MOTOR The sunroof has a bi-directional motor. When the motor is not operating both circuits are grounded. When the motor drives the sunroof glass in the direction from the vent to closed or closed to open position, the following occurs: - Voltage is supplied to the sunroof motor feed open circuit. - Ground is maintained to the sunroof motor feed close circuit. When the motor drives the sunroof in the direction from the open to closed or closed to vent position, the following occurs: - Voltage is supplied to the sunroof motor feed close circuit. - Ground is maintained to the sunroof motor feed open circuit. The sunroof module is equipped with a timer circuit which stops the operation of the sunroof motor after 8 seconds. Page 5005 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Service and Repair Wiper Control Module: Service and Repair WIPER MOTOR MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cover and three screws. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Service and Repair Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 5293 C430 (Chassis Harness To License Lamp Harness) (Export) Page 8959 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 5585 Fuse Block - Underhood Connector C1 Part 2 Page 9543 Steps 5-6 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The Symptom Table will determine the correct diagnostic procedure to use. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 2287 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 2079 Engine Coolant Temperature (ECT) Sensor Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6579 1. Remove the A/C compressor from the vehicle. 2. Clamp the J 41790 in a vise and attach the A/C compressor to the J 41790. 3. Remove the A/C compressor clutch plate and hub assembly. 4. Install the J 33023-A onto the front head of the A/C compressor. 5. Remove the A/C compressor rotor and bearing assembly. 6. Mark the clutch coil terminal location (2) on the A/C compressor front head. 7. Install the J 33025 onto the J 8433. Page 2129 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module (BCM) C2 Part 1 Page 2042 1. Install the heater core to the heater/vent module. 2. Install the heater core access cover. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the heater core access cover screws to 1.9 N.m (17 lb in). 3. Install the heater/vent module. Page 5353 C402 (Body Harness To RH Tail Lamp Harness) (Export) Page 9592 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Testing and Inspection Ignition Cable: Testing and Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Page 2651 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 885 Steps 18-23 Page 9344 Page 4328 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 2318 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Service and Repair Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cargo tie down mounting bolt. 2. Remove the cargo tie down loop. INSTALLATION PROCEDURE 1. Position the cargo tie down loop on the floor. 2. Install the cargo tie down loop to the floor with the mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cargo tie down loop mounting bolt to 35 N.m (26 lb ft). Page 6225 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 8626 3. Engage the hook and loop strips (1) that retain the seat pad (3) to the seat cover (2). 4. Install the seat belt buckle through the slot in the seat. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the seat belt holder bolt. Tighten the seat belt buckle bolt to 70 N.m (52 lb ft). 6. Install the seat back to seat bottom bolts. 7. Install the power seat control switch, if equipped. 8. Install the seat back release lever, if equipped. 9. Install the manual lumbar support knob, if equipped. 10. Connect the electrical connections, as needed. 11. Install the seat back recliner assembly, if equipped. 12. Install the cupholder and bracket, if equipped. 13. Engage the J-strips to the seat bottom frame. 14. Install the trim plate. 15. Install the seat to the vehicle. Page 9025 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The BCM generates the audible warnings through an internal speaker. The BCM emits audible warnings based on various inputs. If the BCM receives multiple audible warning requests, the warning with the highest priority sounds first. Fasten Safety Belt Warning The BCM activates the fasten safety belt audible warning, and also sends a class 2 message to the IPC to illuminate the fasten safety belt indicator when the following occurs: The ignition switch transitions to RUN. - The seat belt is not buckled and the signal circuit is low. If the seat belt is buckled while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to RUN, the chime does not sound. Key-In-Ignition Warning The BCM activates the key-in-ignition audible warning when all of the following occurs: The driver door is open and the signal circuit is low. - The key is in the ignition and the signal circuit is low. The audible warning will sound for as long as the above conditions exist. Lights On Warning The BCM activates the lights on warning when the following occurs: The ignition is not in the RUN or START position. - The headlamp switch is in the PARK or Head position. - The instrument panel dimmer switch is not at the most dim setting. The audible warning will sound for as long as the above conditions exist. Low Fuel Warning The BCM activates the low fuel warning when the following occurs: The ignition is in the RUN or START position. - The fuel level is below 17 percent. - The BCM receives a class 2 message from the PCM requesting an audible warning. Page 4599 9. Remove the rear brake shoes. Installation Procedure 1. Lubricate the brake shoe backing plate with a thin coat of high temperature silicone lubricant. 2. Install the park brake hardware. Page 7302 Registered And Non-Registered Trademarks - Part 1 Page 5091 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 8342 WA812K/88 - WA813K/89 Page 6432 6. Firmly pull on the mode actuator in order to remove the actuator from the HVAC module. INSTALLATION PROCEDURE 1. Install the mode actuator. Ensure that the retaining tabs lock into place. 2. Install the actuator rod (2) to the mode door lever (3). 3. Install the actuator rod retaining clip (4). 4. Connect the vacuum connectors (1) to the mode actuator (5). Page 2727 Step 4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Page 1544 6. Use the J 23523-F in order to remove the crankshaft balancer. 6.1. Install the J23523-F plate and bolts onto the crankshaft balancer. Tighten the bolts to 25 Nm (18 ft. lbs.). 6.2. Install the J23523-F forcing screw into the plate. 6.3. Rotate the J23523-F forcing screw clockwise in order to remove the crankshaft balancer. 7. Remove the J23523-F from the crankshaft balancer. 8. Note the position and length of any front groove pins (crankshaft balancer) (if applicable). 9. Clean the crankshaft balancer in cleaning solvent. 10. Dry the crankshaft balancer with compressed air. 11. Inspect the crankshaft balancer for the following: ^ Loose or improperly installed front groove pin (1) (crankshaft balancer) A properly installed front groove pin should be installed until flush or below flush with the face of the crankshaft balancer. Important: A crankshaft front oil sealing surface with excessive scoring, grooves, rust, or other damage must be replaced. Specifications Pressure Plate: Specifications Use a cries-cross pattern for tightening the bolts. NV1500 transmission Pressure and cover plate bolts ....................................................................................................................................................... 44 Nm (33 ft. lbs.). NV3500 transmission Pressure and cover plate bolts ...................................................................................................................................................... 40 Nm (29 ft. lbs.). Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Locations Shift Solenoid: Locations Steering Column Components Page 5688 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 2 Page 6458 Page 115 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORX mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the E13CM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TOW screws (1) in the EBCM (2). Tighten the four T-25 TOW screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). Page 7588 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Locations Canister Vent Valve: Locations Rear Frame (4-Door) Sunroof Wiring Harness Replacement With RPO Code CF5 Sunroof / Moonroof Wiring Harness: Service and Repair Sunroof Wiring Harness Replacement With RPO Code CF5 SUNROOF WIRING HARNESS REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the negative battery cable. 2. Remove the headliner. 3. Disconnect the wiring harness from the sunroof module (2). 4. Remove the rosebud clips securing the dome lamp/sunroof harness to the left front side door opening frame. 5. Remove the tape securing the sunroof harness to the dome lamp harness 6. Disconnect the wiring harness from the body wiring harness. 7. Remove the wiring harness from the vehicle. INSTALLATION PROCEDURE 1. Install the wiring harness to the dome lamp harness by wrapping the harnesses with electrical tape. 2. Install the wiring harness rosebud clips to the left front side door opening frame. 3. Connect the wiring harness from the body wiring harness. 4. Connect the wiring harness from the sunroof module (2). 5. Install the headliner. 6. Install the negative battery cable. Page 9343 Page 1231 Relay Block - Body Part 1 Page 1147 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 8649 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 6153 1. Install the transmission support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission support to the frame nuts, bolts, and reinforcements, utilities. Tighten the transmission support to the frame nuts to 54 N.m (40 lb ft). 3. Install the transmission support to the frame nuts, bolts, and reinforcement, 4.3 L pickup. Tighten the transmission support to the frame nuts to 54 N.m (40 lb ft). 4. Install the transmission support to the frame nuts, bolts, and reinforcement, 2.2 L. Tighten the transmission support to the frame nuts to 54 N.m (40 lb ft). Page 3312 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite the rotor segment when the driven gear is installed in the distributor. 14. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. Page 8590 2. Remove the rear seatback filler panel retaining nuts. 3. Remove the rear seatback filler panel. INSTALLATION PROCEDURE 1. Install the rear seatback filler panel. 2. Install the rear seatback filler panel retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seatback filler panel retaining nuts to 80 N.m (59 lb ft). Seat Back Recliner Handle Replacement - Front SEAT BACK RECLINER HANDLE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the handle retaining screw. Page 9571 Page 8213 1. Remove the upper and lower rear seat belt anchor bolts. 2. Remove the endgate or the liftgate opening door sill trim plate. 3. Remove the jack storage cover (driver side only). 4. Remove the screws that retain the body side trim panel to the vehicle (driver side only). 5. Remove the spare tire and the carrier assembly (if equipped). 6. Remove the left and right body side trim panel from the vehicle. 7. Feed the seat belt through the trim panel. INSTALLATION PROCEDURE 1. Install the body side trim panel to the vehicle. 2. Feed the seat belt through the trim panel. 3. Install the screws that retain the body side trim panel to the vehicle (left side only). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 4. Install the spare tire and the carrier assembly (if equipped). 5. Install the jack storage cover (left side only). 6. Install the endgate or liftgate opening door sill trim plate. 7. Install the upper and lower rear seat belt anchor bolts. Tighten Tighten the upper bolts to to 70 N.m (52 lb ft). - Tighten the lower bolts to to 80 N.m (59 lb ft). Trim Panel Replacement - Left Hinge Pillar Trim Panel Replacement - Left Hinge Pillar Page 1609 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 6062 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 3825 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side Locations Oxygen Sensor: Locations Heated Oxygen Sensors (HO2S) Page 4980 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4992 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 3315 10. Remove the mounting clamp hold down bolt. 11. Remove the distributor. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than 1 clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving proper rotor alignment during the distributor installation. INSTALLATION PROCEDURE 1 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the 2 marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). Locations Steering Column Components Page 3852 Page 4531 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal Injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km1h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 2883 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Page 3874 ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Procedures Seat Back: Procedures Seat Back Cover and Pad Replacement - Front SEAT BACK COVER AND PAD REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the head restraint, if equipped, from the seat back. 2. Remove the EZ entry release handle, if equipped, from the seat back. 3. Separate the J-strip at the base of the seat back. 4. Remove the seat cover from the pad by sliding the cover upward off the seat back. 5. Remove the seat back cardboard by unhooking the plastic clips from the lumber support. 6. Separate the seat back pad from the seat back frame. Specifications Engine Block Heater: Specifications Engine Block Coolant Drain Hole Plug 20 Nm (15 ft. lbs.) Engine Block Left Rear Oil Gallery Plug ................................................................................................................................................. 30 Nm (22 ft. lbs.) Engine Block Left Side Oil Gallery Plug .................................................................................................................................................. 20 Nm (15 ft. lbs.) Engine Block Oil Gallery Plug ............................................................................................ ..................................................................... 20 Nm (15 ft. lbs.) Engine Block Right Rear Oil Gallery Plug ............................................................................................................................................... 20 Nm (15 ft. lbs.) Engine Coolant Heater Bolt/Screw ......................................................................................................................................................... 2 Nm (18 inch lbs.) Page 2102 ^ Do not damage the screen located on the air inlet end of the MAR ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 19. Install air cleaner outlet duct to throttle body. 20. Install air cleaner outlet duct to MAF sensor. 21. Connect the IAT sensor harness connector. 22. Install the air cleaner outlet duct retaining wingnut. Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Page 4855 Service and Repair Cross-Member: Service and Repair Transmission Support Replacement (RWD) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Install the transmission jack to the transmission and support the transmission. 3. Disconnect the transmission wiring harness from the transmission support, if necessary. 4. Remove the transmission mount to the transmission support stud nut, 2.2 L. 5. Remove the transmission mount to the transmission support stud nut, 4.3 L pickup and utilities. 6. Remove the catalytic converter hanger bracket from the transmission support mounting bolts, 2.2 L if necessary. Page 9403 Abbreviations And Meanings - Part 16 Page 8415 Heated Seat Control Module Driver/Front Passenger (Part of the Heated Seat Control Module) Driver/Front Passenger (Part of the Heated Seat Assembly) Page 1006 3. Tighten the air cleaner cover wingnuts. A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 1133 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 9118 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5202 Fuse Block: Application and ID Underhood Fuse Block Fuse Block - Underhood Details (Uplevel Utility) Application Table Part 1 Page 3114 INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male pipe end. CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting. Page 6375 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Service and Repair Positive: Service and Repair BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the positive battery cable from the battery. 3. Remove the bolt retaining the positive battery cable to the underhood fuse block. 4. Remove the nut retaining the positive battery cable to the generator. 5. Raise and support the vehicle. Refer to Vehicle Lifting. Body - Hood Hinge Rattling Noises Hood Hinge: All Technical Service Bulletins Body - Hood Hinge Rattling Noises Bulletin No.: 01-08-63-001B Date: December 12, 2005 TECHNICAL Subject: Hood Hinge Rattle (Install Spring Washer) Models: 1995-2004 Chevrolet S-10 1995-2005 Chevrolet Blazer 1995-2004 GMC Sonoma 1995-2005 GMC Jimmy 1996-2002 Oldsmobile Bravada (Plant Codes 8 and K) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-08-63-001A (Section 08 - Body and Accessories). Condition Some customers may comment on a rattle coming from either or both front corners of the instrument panel near the hood hinge areas. This noise may often be mistaken for a loose shock absorber. The rattle may be heard when driving over rough roads and is most noticeable when the road surface creates a side-to-side vehicle motion. Cause Excessive clearance at the hood hinge attaching bolt may cause this condition. The excessive clearance allows the hood hinge to make metal contact with the hood hinge bracket, which produces a rattling noise. Correction Important: For additional information, see the Body Front End subsection of the Body and Accessories Section of the appropriate Service Manual. 1. Remove the hood hinge attaching bolt (1). 2. Install a spring washer (2) on the bolt as shown in above illustration. 3. Install the bolt. Tighten Page 1366 Disclaimer Page 7859 6. Remove the lower latch bolt (2). 7. Remove the latch (1) and rod (2) from the door. 8. Remove the latch rod (3) from the retainer on the latch. Installation Procedure 1. Install the latch rod (3) to the retainer on the latch. 2. Install the latch (1) and rod to the door. 3. Loose start the upper latch bolt. (4). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the lower latch bolt (2). Page 189 4. Disconnect the PCM electrical connectors. Installation Procedure 1. Remove the replacement PCM from the packaging. 2. Check the service number in order to make sure the service number is the same number as the defective PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM electrical connectors screws to 8 N.m (71 lb in). Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 8697 Abbreviations And Meanings - Part 17 Page 8694 Abbreviations And Meanings - Part 14 Procedures Drink Holders: Procedures CUPHOLDER REPLACEMENT - FRONT FLOOR CONSOLE REMOVAL PROCEDURE Pull up on the lower edges of the cup holder in order to release the retaining clips and remove the cup holder from the vehicle. INSTALLATION PROCEDURE Install the front floor cup holder to the vehicle. Page 9693 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 9730 Abbreviations And Meanings - Part 20 Page 2817 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 5745 C211 (Steering Column Harness To Body Harness) Part 3 Locations Floor Pedals Page 9547 Steps 9-12 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 9143 Abbreviations And Meanings - Part 21 Page 644 Engine, LR Page 539 Transmission Range Switch (W/ A/T) Service and Repair Throttle Cable/Linkage: Service and Repair ACCELERATOR CONTROLS CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the accelerator cable from the throttle body. 3. Remove the accelerator cable from the accelerator control cable bracket. Page 7878 Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Upper Sealing Strip Replacement - Rear Door Upper Removal Procedure Pull the weatherstrip from the door frame. Installation Procedure Push the weatherstrip molding over the door frame. Page 2295 Throttle Position (TP) Sensor Page 1246 Application Table Part 5 Service and Repair Housing Assembly HVAC: Service and Repair HEATER/VENT MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the blower motor resistor. 4. Remove the heat/vent module mounting bolt through the blower motor resistor or service access cover opening. IMPORTANT Mark and use the same mounting bolt for the heater/vent module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door. 5. Remove the right wheel house panel. 6. Remove the front right tire. 7. On the Utility only, remove the A/C evaporator and blower module heat shield screws. 8. On the Utility only, slide the A/C evaporator and blower module heat shield toward the front of the vehicle. 9. Remove the 2 lower heat/vent module mounting nuts. 10. On the Utility only, remove the A/C evaporator and blower module heat shield bracket. Locations Door Wiring Harness (RR Shown, LR Similar) Page 1730 Engine Harness Rear (4.3L) Page 5183 Fuse Block - Underhood Connector C3 Part 2 Page 4549 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 4987 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Locations Instrument Panel Details, RH Page 9819 Abbreviations And Meanings - Part 5 Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) Step 1 - 7 Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9958 7. Remove the washer pumps and grommets from the solvent container. INSTALLATION PROCEDURE 1. Install the washer pumps and grommets onto the solvent container. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the solvent container onto the vehicle with the screw. Page 4093 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 5176 Fuse Block - Underhood Connector C1 Part 7 Page 6489 Arrows And Symbols Uses various symbols in order to describe different service operations Page 7948 Hood Latch: Service and Repair Hood Pop-Up Spring Replacement Hood Pop-Up Spring Replacement Removal Procedure 1. Use a flat-bladed tool in order to push in the hood mounted end of the spring in order to release the retainers. 2. Remove the spring from the hood. Installation Procedure 1. Position the spring to the hood. 2. Insert the spring into the hood retainers. Page 6034 Page 5671 C204 (Floor Shifter Harness To Body Harness) (Utility and Crew Cab) Page 7796 Tighten the screw to 1.9 N.m (17 lb in). Page 5550 Registered And Non-Registered Trademarks - Part 2 Page 1925 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 1078 1. Install the radiator outlet hose. 2. Using the J 38185 reposition the radiator outlet hose clamp to the water pump. 3. Using the J 38185 reposition the radiator outlet hose clamp to the radiator. 4. Fill the cooling System. Page 3033 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Page 2995 Canister Vent Valve: Service and Repair EVAP Canister Vent Valve Replacement (4-Door) REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Raise the vehicle. 3. Remove the spare tire, underbody mounted spare tire only. 4. Disconnect the evaporative emission (EVAP) canister vent valve harness connector. 5. Disconnect the vent hose (1) from the EVAP canister vent valve (2). 6. Release the tang on the vent bracket (4). 7. Remove the vent valve (2) from the bracket (4). INSTALLATION PROCEDURE 1. Slide the vent valve (2) onto the bracket (4). 2. Test the EVAP canister vent valve retention to the vent bracket (4). 3. Connect the EVAP vent hose (1) to the EVAP canister vent valve (2). 4. Connect the EVAP canister vent valve harness connector. 5. Raise the spare tire, underbody mounted spare tire only. 6. Lower the vehicle. Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EBCM to BPMV 39 inch lbs. EHCU to Bracket 7 ft. lbs. Page 6021 Steering Gear Seal: Service and Repair Pitman Shaft Seal Replacement - On Vehicle ^ Tools Required J 4245 Internal Snap Ring Pliers - J 6219 Pitman Shaft Oil Seal Installer Removal Procedure 1. Remove the pitman arm from the pitman shaft. 2. Remove the snap ring (1) using J 4245. 3. Place a drain pan under the steering gear. 4. Start the engine. 5. Turn the steering wheel from stop to stop. Bounce the wheel off the stops. 6. Turn OFF the engine. 7. Remove the following components from the power steering gear (1): ^ The dust seal (5) ^ The return ring (4) ^ The washer (3) ^ The pitman shaft oil seal (2) 8. Inspect the pitman shaft seal surfaces for roughness or pitting. Replace the pitman shaft if the shaft is pitted. 9. Clean the pitman shaft and seal areas using a wire brush. Installation Procedure 1. Lubricate the new seals with grease. 2. Apply a single layer of tape to the pitman arm shaft in order to avoid damaging the seals. Page 9952 Windshield Washer Pump: Service and Repair WASHER PUMP/RESERVOIR REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the hood. 2. Remove the washer solvent from the solvent container. 3. Disconnect the electrical connectors from the washer pumps. 4. Disconnect the hoses from the washer pumps. 5. Remove the screw retaining the solvent container to the vehicle. 6. Remove the solvent container from the vehicle. Page 8336 WA711J/58 - WA722J/25 Page 6727 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (5) from the accumulator. INSTALLATION PROCEDURE 1. Install the A/C low pressure switch (5) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the A/C low pressure switch to................5 N.m (44 lb in). 2. Connect the A/C low pressure switch electrical connector. 3. Leak test the fittings of the component using the J 39400-A. Page 5357 C412 (Endgate Harness To Body Harness) Page 8947 Page 6368 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage Page 5066 IP Fuse Block Details Fuse: Application and ID IP Fuse Block Details Location View Application Table Part 1 Page 803 Abbreviations And Meanings - Part 12 Page 1543 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement ^ Tools Required - J 23523-F Balancer Remover and Installer Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the fan shroud assembly. 3. Remove the drive belt. Notice: To prevent damage to the end of the crankshaft when using a crankshaft balancer removal tool install a bolt in the crankshaft. Use a shorter bolt with the same threads as the crankshaft balancer bolt. This bolt will allow a place for the tool to push against. The shorter bolt is to keep from going past the threads in the crankshaft and damaging the crankshaft threads. 4. Remove the crankshaft balancer bolt and washer. 5. Remove the bolts and the crankshaft pulley. Notice: Refer to Fastener Notice in Service Precautions. Page 930 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 6909 Inflatable Restraint Front End Discriminating Sensor - Right Page 3227 INSTALLATION PROCEDURE 1. Install the accelerator cable (1) through the bulkhead (4). 2. Install the accelerator cable panel insulator retainer (2) on the accelerator cable (1). 3. Install the accelerator cable to the accelerator pedal (2). 4. Connect the accelerator cable (1) to the bracket clip (2). Page 4458 1. Install sensor into the hub and bearing assembly (6). Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. 8. Lower the vehicle. Refer to Vehicle Lifting. Page 8162 1. Install the headliner to the vehicle. New headliners must be pierced in order to accommodate actual vehicle accessories. 2. Install the rear upper garnish molding. 3. Install the upper body side panel trim. 4. Install the inside air temperature sensor grille. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear seat upper seat belt anchor bolts (2-door models only). Tighten the bolts to 70 N.m (52 lb ft). 6. Install the body lock pillar trim panels 4-door models only). 7. Install the windshield garnish moldings. 8. Install the sunshades and the retainers. 9. Install the assist handles. 10. Install the coat hooks. 11. Install the sunroof opening trim, if equipped, by carefully pressing it into place. 12. Install the dome lamp, if equipped. 13. Install the overhead or sunroof console, if equipped. Page 4498 14. Remove the brake caliper mounting bolt sleeves. 15. Remove the rubber O-rings. 16. Discard the rubber O-rings. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent. 2. Dry the brake caliper pin bolts using non-lubricated, compressed filter air. 3. Lubricate the sleeves and bushings with Delco Silicone Lube, GM P/N 18010909, or equivalent. 4. Install the rubber O-ring bushings to the brake caliper. 5. Install the brake caliper mounting bolt sleeves. 6. Install the brake pads to the brake caliper. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the brake caliper mounting bolts. Tighten the brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Brake Hose Installation Notice in Service Precautions. Page 2353 Page 363 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 8677 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 7135 Registered And Non-Registered Trademarks - Part 1 Page 7995 Trunk / Liftgate Latch: Service and Repair Latch Support Replacement - Lift Gate Window Latch Support Replacement - Lift Gate Window Removal Procedure 1. Remove the liftgate window latch. 2. Disconnect the electrical connectors as needed. 3. Mark the location of the liftgate window latch support in order to ensure proper alignment during installation. 4. Remove the bolts that retain the liftgate window latch support to the liftgate. 5. Remove the liftgate window latch support from the liftgate. Installation Procedure 1. Align the marks made during disassembly in order to install the liftgate window latch support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the liftgate window latch support to the liftgate. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the electrical connectors as needed. 4. Install the liftgate window latch. Trim Panel Replacement - End Gate Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel Replacement - End Gate Trim Panel Replacement - End Gate Removal Procedure 1. Open the endgate. 2. Remove the screws that retain the inside handle to the endgate. 3. Remove the endgate inside handle from the endgate. 4. Remove the screw that retains the endgate trim panel to the endgate window latch support. 5. Remove the screws that retain the endgate trim panel to the endgate. 6. Remove the endgate trim panel from the endgate: 1. Release the retaining clips from the upper edge and the sides of the trim panel. 2. Lift the panel up in order to release the tabs along the bottom edge. Installation Procedure 1. Install the endgate trim panel to the endgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the endgate trim panel to the endgate. Tighten the screws to 1.9 N.m (17 lb in). 3. Install the screw that retains the endgate trim panel to the endgate window latch support. Tighten the screw to 1.9 N.m (17 lb in). 4. Install the endgate inside handle to the endgate. Tighten the handle to 2.8 N.m (25 lb in). Page 7075 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Diagram Information and Instructions Information Bus: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Diagrams Power Mirror Switch: Diagrams Outside Rearview Folding Mirror Switch (Export) Specifications Clutch Fluid: Specifications Hydraulic Clutch System Hydraulic Clutch Fluid (GM Part No. 12345347, in Canada 10953517, or equivalent DOT-3 brake fluid). Page 9106 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 4543 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 1850 Steps 4-7 Page 8358 WA9539/47 - WA9792/39 Page 8973 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 447 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Page 3145 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to the Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Note the position of the fuel strainer (2) on the fuel sender. 7. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand. 8. Pull the strainer off the fuel sender. Discard the strainer after inspection. 9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. INSTALLATION PROCEDURE 1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated. 2. Install the fuel sender assembly. 3. Install the fuel tank. 4. Refill the fuel tank. Page 8338 WA765J/37 - WA800J/98 Page 3151 9. Pull straight up on the fuel pipes in order to remove the fuel pipes from the injector assembly. 10. Remove the O-ring seals from both ends of the fuel feed and return pipes. 11. Discard the O-ring seals. INSTALLATION PROCEDURE 1. Assemble the new O-rings into the inlet and outlet of the fuel injector assembly. 2. Apply a few drops of clean engine oil to the male tube ends. 3. Install the fuel feed and return pipes to the injector assembly. 4. Install the fuel pipe retainer and the attaching nuts. Page 4909 Abbreviations And Meanings - Part 9 Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 3962 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 9567 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Page 9696 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 5034 Abbreviations And Meanings - Part 23 Page 5997 13. Loosen the accessory mounting bracket bolts and nuts and pull accessory mounting bracket forward. 14. Remove the power steering pump and power steering pressure hose from the vehicle. Important: Note the position of the power steering pressure hose to the power steering pump to ensure proper installation to the vehicle. 15. Remove the power steering pressure hose from the power steering pump. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power steering pressure hose to the power steering pump. Tighten the power steering pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). 2. Install the power steering pump and power steering pressure hose to the vehicle. 3. Reposition the power steering pump mounting bracket and tighten the power steering pump mounting bracket mounting bolts and nut. Tighten the power steering pump mounting bracket mounting bolts and nut to 41 Nm (30 ft. lbs.). 4. Install the power steering pump front mounting bolts. Diagram Information and Instructions Alternator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Service and Repair Pilot Bearing: Service and Repair Pilot Bearing Replacement ^ Tools Required J 43276 Clutch Pilot Bearing Remover - J26516-A Clutch Pilot Bearing Installer - J 8092 Driver Handle Removal Procedure 1. Remove the Flywheel. Caution: Refer to Safety Glasses Caution in Service Precautions. Notice: When using the J 43276 Clutch Pilot Bearing Remover always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so will cause damage to the J 43276-1 tool body. 2. Remove the clutch pilot bearing using the J 43276. 2.1. Install the J 43276-1 tool body into the clutch pilot bearing. 2.2. Using a wrench secure the J 43276-1 tool body. 2.3. Insert the J 43276-2 forcing screw into the J 43276-1 tool body. 2.4. Rotate the J 43276-2 forcing screw clockwise into the J 43276-1 tool body until the clutch pilot bearing is completely removed from the crankshaft. 2.5. Rotate the J 43276-2 forcing screw counterclockwise to remove the J 43276-2 forcing screw from the J 43276-1 tool body. 2.6. Remove the J 43276-1 tool body from the clutch pilot bearing. 3. Discard the clutch pilot bearing. Installation Procedure Caution: Refer to Safety Glasses in Service Precautions. Page 1804 5. Remove the camshaft sprocket bolts. 6. Remove the camshaft sprocket and the camshaft timing chain. 7. Remove the crankshaft sprocket using the J 5825-A. Page 5245 C201 (Steering Column Harness To Redundant Steering Wheel Control Harness) C203 - Body Harness to IP Harness A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 149 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 5072 Page 9683 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 1389 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 5932 1. Install the upper ball joint to the steering knuckle. 2. Install the lower ball joint to the steering knuckle. 3. Install the splash shield to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the splash shield bolts. Tighten the splash shield bolts to 26 Nm (19 ft. lbs.). 5. Install the tie rod end to the steering knuckle. Ensure that the seal is on the stud. 6. Seat the taper using J 29193. Tighten J 29193 to 54 Nm (40 ft. lbs.). Remove J 29193 from the tie rod end ball stud. 7. Install the tie rod end retaining nut. Tighten the tie rod end retaining nut to 53 Nm (39 ft. lbs.). 8. Install the rotor. 9. Lower the vehicle. 10. Check the front wheel alignment. Specifications Compression Check: Specifications Compression Pressure Limit ............................................................................................................... ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest. Service and Repair Resonator: Service and Repair AIR CLEANER OUTLET RESONATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the breather tube from the air cleaner outlet duct. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the air cleaner outlet duct retaining wingnut. Page 635 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 5107 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 8065 7. Remove the catalytic converter hanger bracket from the transmission support mounting bolts, 4.3 L if necessary. 8. Remove the transmission support to the frame nuts, bolts, and reinforcement, 2.2 L. 9. Remove the transmission support to the frame nuts, bolts, and reinforcement, 4.3 L pickup. 10. Remove the transmission support to the frame nuts, bolts, and reinforcements, utilities. 11. Remove the transmission support. Installation Procedure Page 5476 Page 5306 C109 (Body Harness To The 4WAL/SIR Harness) Page 5901 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-I). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is louver than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height. The front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at thigh speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Toe Description Toe Description Page 8912 Tighten Tighten the cruise control module nuts to 9.0 N.m (6.6 lb ft). 4. Connect the electrical connector. 5. Install the cruise control cable. 6. Connect the battery negative cable. 7. Test the systems operation. Page 7269 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4291 Page 4058 Page 3739 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 5215 1. Install the ground strap. 2. Install the ground strap bolt to the cowl. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ground strap to cowl bolt to 17 N.m (12 lb ft). 3. Raise the vehicle. 4. Install the ground strap bolt to the engine. Tighten Tighten the ground strap bolt to 50 N.m (37 lb ft). 5. Lower the vehicle. Page 4654 1. Install the new bushing and sleeves. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front brake caliper bracket mounting bolts, lower shown. Tighten the brake caliper mounting bracket bolt to 180 Nm (133 ft. lbs.). 3. Install the brake pad assembly. 4. Install the tire and wheel assembly. 5. Lower the vehicle. Refer to Vehicle Lifting. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6 and 7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the brake master cylinder to the proper level. Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Page 5728 C203 (Body Harness To IP Harness) Part 2 Page 5475 Page 5992 4. Remove the control valve assembly (3) and the flow control spring (2) from the pump housing assembly (1). Assembly Procedure 1. Install the flow control spring (2) to the pump housing assembly (1). 2. Install the control valve assembly (3) to the flow control spring (2). 3. Install the O-ring seal (3) to the connector and fitting assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the connector and fitting assembly (4) to the pump housing (1). Tighten the connector and fitting assembly (4) to 75 Nm (55 ft. lbs.). Page 9383 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6583 16. Use the J 6083 in order to install the following components: - The pulley rotor (1) - The retainer ring (2) 17. Install the clutch plate and hub assembly. V7 - Direct Mount COMPRESSOR CLUTCH COIL INSTALL (V7 - DIRECT MOUNT) TOOLS REQUIRED - J 8433 A/C Compressor Pulley Puller - J 8433-3 Forcing Screw - J 33024 Clutch Coil Installer Adaptor - J 33025 Clutch Coil Puller Legs - J 41790 A/C Compressor Holding Fixture - J 42136A/C Lip Seal Remover 1. Place the clutch coil assembly (1) on the front head with the clutch coil terminal positioned at the mark made during disassembly. 2. Place the J 33024 over the internal opening of the clutch coil housing and align installer with the A/C compressor front head. 3. Install the J 8433-3 into the J 8433 and center the screw in the countersunk center hole of the J 33024. 4. Install the 4 inch through bolts and washers from the J 42136 tool kit into the J 33025 and attach them to the A/C compressor mounting bosses. 5. Turn the center forcing screw of the J 8433 to press the clutch coil onto the front head until the clutch coil is fully seated. Make sure the clutch coil and the J 33024 stay in-line with each other while pressing the clutch coil onto the A/C compressor. 6. Install the A/C compressor clutch rotor and bearing assembly. 7. Install the A/C compressor clutch plate and hub assembly. 8. Remove the A/C compressor from the J 41790. 9. Install the A/C compressor into the vehicle. Page 2516 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 863 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-I). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is louver than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height. The front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at thigh speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Toe Description Toe Description Page 3592 3.2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. 6. Enable the SIR system. Specifications Idler Pulley: Specifications Drive Belt Idler Pulley Bolt ................................................................................................................... ................................................... 50 Nm (37 ft. lbs.) Page 3097 Step 6 Page 7634 Page 2167 Ignition Control Module: Description and Operation IGNITION COIL AND ICM The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 5265 C211 (Steering Column Harness To Body Harness) Part 4 Page 775 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 1462 Vehicle Lifting: Service and Repair Vehicle Lifting Points VEHICLE LIFTING POINTS The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and Diagrams Power Seat Motor Position Sensor: Diagrams Seat Front Vertical Position Sensor - Driver (w/ Memory) Page 4614 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 lbs.), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 9766 Page 5551 Registered And Non-Registered Trademarks - Part 3 Page 1849 Steps 1-3 Page 2251 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Disconnect the fuel tank pressure sensor electrical connector. 6. Remove the fuel tank pressure sensor (1) from fuel sender assembly (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) on the fuel sender assembly (2). 2. Connect the fuel tank pressure sensor electrical connector. 3. Install the fuel tank. 4. Refill the fuel tank. 5. Install the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 837 Windshield Washer Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Use a flat-bladed tool in order to pry the switch away from the instrument panel. 3. Disconnect the electrical connectors as necessary. INSTALLATION PROCEDURE 1. Connect the electrical connectors as necessary. 2. Install the switch to the instrument panel. 3. Connect the negative battery cable. Page 7772 2. Install the molding to the quarter panel rear window (4-Door only). 3. Install the molding fasteners to the quarter panel rear window (4-Door only). 4. Install the body side stationary window (2-Door only). Engine/Transmission - Flexplate/Flywheel Replacement Flywheel: Technical Service Bulletins Engine/Transmission - Flexplate/Flywheel Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-003 Date: February, 2003 INFORMATION Subject: Flywheel/Flexplate Replacement Models: 2003 Passenger Cars and Light Trucks When replacing the starter for any reason, the flywheel/flexplate should be inspected before replacement. The flywheel/flexplate should be turned a full 360 degrees and inspected for missing or broken teeth or signs of starter milling on the sides of the teeth before replacement. No flywheel/flexplate should be replaced without a visual defect. The majority of flywheel/flexplates returned to GM after replacement under warranty show no signs of damage or defect. Disclaimer Page 4192 1. Note the position of the flywheel weights and install the NEW flywheel weights as required. A properly installed flywheel weight will be flush or slightly below flush with the face of the engine flywheel. 2. Install the engine flywheel (1 or 2) to the crankshaft. Align the engine flywheel locator hole to the flywheel locator pin. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine flywheel bolts. Tighten the engine flywheel bolts in sequence to 100 Nm (74 ft. lbs.). 4. Install the clutch assembly, if equipped. 5. Install the transmission. Page 6767 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Page 7102 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4999 Equivalent - Decimal And Metric Part 2 Diagrams Rear Wiper/Washer And Endgate Window Release Switch Page 9093 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 205 Air Bag Control Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Page 5231 C101 (Body Harness To Engine Harness) Part 2 Page 5127 Abbreviations And Meanings - Part 20 Page 9493 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 4314 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 5012 Abbreviations And Meanings - Part 1 Page 7279 Abbreviations And Meanings - Part 5 Page 5090 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 3426 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ....................................................... ACDelco 41-948 Page 5659 C201 (Steering Column Harness To Redundant Steering Wheel Control Harness) C203 - Body Harness to IP Harness Page 1756 12. Loosely install the power steering pump mounting bracket bolts and nuts. 13. Install the nut for the power steering pump rear bracket at the front of the engine. Tighten the power steering pump mounting bracket bolts and the power steering pumps rear bracket nuts to 41 Nm (30 ft. lbs.). 14. Install the drive belt. 15. Install the fuel supply and return pipes to the rear of the intake manifold. Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center. 16. Remove the spark plug for number one cylinder. 17. Rotate the crankshaft until number one cylinder is in the compression stroke. 18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover. 19. Install the spark plug. 20. Install the distributor 21. Install the Evaporative Emission (EVAP) canister purge solenoid valve. Page 6776 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 7763 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper Removal Procedure 1. Remove the license lamps. 2. Remove all of the step pads from the bumper. 3. Remove the clips securing the fascia at the bottom of the impact bar. 4. Remove the fascia. Installation Procedure 1. Install the fascia to the impact bar with the clips on the bottom edge of the fascia. 2. Install the step pads to the bumper. 3. Install the license lamps. Powertrain Control Module (PCM) Connector C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C1 Powertrain Control Module (PCM) Connector C1 Part 1 Service and Repair Vacuum Reservoir HVAC: Service and Repair VACUUM TANK REPLACEMENT REMOVAL PROCEDURE 1. Remove the brake pressure modulator valve. 3. Using a flat-bladed tool, depress the retaining tabs in order to remove the vacuum tank. INSTALLATION PROCEDURE 1. Install the vacuum tank. Ensure that the retaining tabs lock into place. OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1444 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Page 9340 Page 7082 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8056 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (Extended Cab) Frame Cushion or Insulator Replacement (Extended Cab) Removal Procedure Properly support the frame when you change the frame cushions. If only one cushion is changed, lower the entire side on which the cushion in placed in order to provide clearance for the cushion. 1. Raise the vehicle slightly on a hoist. Refer to Vehicle Lifting. 2. Place jack stands under the body on the side of the vehicle that the cushions will be placed. 3. Remove the frame cushion bolts. 4. Remove the retainer. 5. Remove the lower cushion. 6. Lower the hoist enough in order to leave the body supported by the jack stands. 7. Remove the upper cushion. 8. Remove the shims, if equipped. Installation Procedure 1. Install the shims, if equipped. 2. Install the upper cushion. A/C Refrigerant Filter Installation Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT:The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the PCM. 2. Remove the engine coolant reservoir. 3. Loosen the accumulator nut at the evaporator. 4. Reposition the accumulator (4) in order to gain access to the evaporator tube (1). 5. Measure 100 mm (4 in) from the bend after the high side access port and mark the location. 6. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. 7. Using a tubing cutter, cut the marked section of the evaporator tube (1). IMPORTANT:Do not allow metal burrs to enter the tube during cutting or when removing the burrs. 8. Remove the burrs from the evaporator tube (1). 9. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). 10. Push the nuts (4), and the ferrules (3) over each of the evaporator tube halves. IMPORTANT:DO NOT install the O-rings (2) in this step. 11. Install the ferrules (3) with the small end toward the nut (4). Page 628 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 7068 Page 7259 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Step 1 - 15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the Page 8651 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Page 9628 Abbreviations And Meanings - Part 9 Page 8974 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 9377 Arrows And Symbols Uses various symbols in order to describe different service operations Page 6946 Disclaimer Page 771 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 4068 Valve Body: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 8092 Mat/Carpet Replacement - Front Floor (Utility) Removal Procedure 1. Remove the front seats. 2. Remove the rear seats. 3. Remove the rear seat belt buckles from the floor. 4. Remove the door sill trim plates. 5. For 4-door models, remove the front side door lock pillar garnish moldings. Refer to Garnish Molding Replacement - Side Door Lock Pillar (CF5). 6. For 4-door models, remove the C-pillar lower trim panels. Refer to Trim Replacement - Third Pillar (Extended Cab Pickup w/ Rear Side Door) Trim Replacement - Third Pillar (4-Door Utility). 7. Remove the body side trim panels as necessary. 8. Remove the floor console or cup holder, if equipped. 9. Remove the body hinge pillar trim panels. 10. Remove the carpet or mat from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet or the mat to the vehicle. 2. Install the body hinge trim panels. 3. Install the floor console or cup holder, if equipped. 4. Install the body side trim panels as necessary. 5. For 4-door models, install the C-pillar lower trim panels. Refer to Trim Replacement - Third Pillar (Extended Cab Pickup w/ Rear Side Door) Trim Replacement - Third Pillar (4-Door Utility). 6. For 4-door models, install the front side door lock pillar garnish moldings. Refer to Garnish Molding Replacement - Side Door Lock Pillar (CF5). 7. Install the door sill trim plates. 8. Install the rear seat belt buckles to the floor. 9. Install the rear seats. 10. Install the front seats. Carpet Replacement - Rear Carpet Replacement - Rear Page 1757 22. Install the PCV hose assembly to the intake manifold and the valve rocker arm cover. 23. Install the accelerator cable and cruise control cable bracket to the throttle body. Tighten the accelerator cable and cruise control bracket nuts to 9 Nm (80 inch lbs.). 24. Install the accelerator cable bracket to the intake manifold and the throttle body. Tighten the accelerator cable bracket studs and nuts to 12 Nm (106 inch lbs.). 25. Position the engine wiring harness. 26. Install the engine wiring harness clips in the brackets. Page 9497 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Locations Electronic Components Page 4213 5. Remove the seal from the front bearing retainer by using a hammer and a punch. 6. Remove the old gasket material from the front bearing retainer. Installation Procedure Important: Inspect the bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. 1. Place the seal in the front bearing retainer. 2. Using the J 38801 install the seal. 3. Apply RTV gasket material to the inboard side of the bearing retainer. Notice: Refer to Fastener Notice in Service Precautions. Page 7658 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 7557 For vehicles repaired under warranty, use the table. Disclaimer Page 4202 4. Apply sealant to the oil fill plug threads. Use Teflon GM P/N 1052080 or the equivalent. 5. Use the J 36511 in order to install the oil fill plug. ^ Tighten the oil fill plug to 30 Nm (22 ft. lbs.). 6. Remove the safety stands. 7. Lower the vehicle. Page 3869 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Locations Relay Block - Body Relays, Except Envoy Page 6985 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(tm) sensor is inside the upper right side of the steering column. The Passlock(tm) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(tm) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(tm) sensor in order to help prevent tamper to the system. Passlock(tm) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(tm) sensor will generate a unique Passlock(tm) code. All 10 combinations of the Passlock(tm) sensor have the same part number. However, you cannot simply replace the Passlock(tm) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 4339 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: Customer Interest A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 410 Page 3616 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 816 Abbreviations And Meanings - Part 25 Page 4406 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the two electrical harness connectors from the EBCM (2). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 2. Disconnect the 5 brake lines from the BPMV (3). 3. Remove 2 bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 4. Disconnect the 2 way ABS pump motor connector. 5. Remove the four T-25 TORX screws (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 7. Clean the EBCM (2) to BPMV (3) mounting surfaces with a clean cloth. Installation Procedure Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) onto BPMV (3). Page 6454 Page 381 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner outlet duct. 3. Disconnect the A/C high pressure switch electrical connector (2). 4. Remove the A/C high pressure switch connector retaining ring. 5. Remove the A/C high pressure switch from the A/C compressor. INSTALLATION PROCEDURE 1. Install the A/C high pressure switch to the A/C compressor. 2. Install the A/C high pressure switch connector retaining ring. 3. Connect the A/C high pressure switch electrical connector (2). 4. Install the air cleaner outlet duct. 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings of the components using the J 39400-A. Page 387 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (5) from the accumulator. INSTALLATION PROCEDURE 1. Install the A/C low pressure switch (5) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the A/C low pressure switch to................5 N.m (44 lb in). 2. Connect the A/C low pressure switch electrical connector. 3. Leak test the fittings of the component using the J 39400-A. Locations Throttle Position Sensor: Locations Engine, LR Page 2633 Page 9367 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 1502 Installation Procedure Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. 1. Install the valve pushrods. Important: Be sure that the arrow on the valve rocker arm support is in the up position. 2. Install the valve rocker arm supports. 3. Apply prelude GM P/N 12345501 (Canadian P/N 992704) or equivalent to the following valve rocker arm contact surfaces: ^ Valve pushrod socket (1) ^ Roller pivot (2) ^ Valve stem tip (3) Page 4757 3. Install the electrical connector. 4. Install the knee bolster trim panel. Page 8209 1. Remove the upper and lower front seat anchor bolts. 2. Remove the rear seat belt lower anchor nut. 3. Remove the assist handle. 4. Remove the coat hook. 5. Remove the endgate or the liftgate opening door sill trim plate. 7. Remove the jack storage cover (left side only). 8. Remove the screw that retains the upper body side trim body side trim panel to the vehicle (left side only). 9. Remove the upper body side trim panel from the vehicle. 10. Feed the seat belt through the trim panel. 11. Remove the body side front lower trim panel from the vehicle. Installation Procedure 1. Install the body side front lower trim panel to the vehicle. 2. Install the upper body side trim panel to the vehicle. 3. Feed the seat belt through the trim panel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screw that retains the upper body side trim panel to the vehicle. Tighten the screw to 1.9 N.m (17 lb in). Page 3573 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 1808 sprocket. 7.3. Remove the bolt that was installed in the end of the crankshaft. 7.4. Install the engine front cover. Page 3164 3. Install the fuel fill pipe to fill pipe housing attaching screws. Tighten Tighten the fuel fill pipe to fill pipe housing screws to 1.9 N.m (17 lb in). 4. Install the fuel filler cap. 5. Connect the negative battery cable. 6. Inspect for leaks. Page 3168 Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement (2-Door) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Drain the fuel below the level of the fuel fill hose. Refer to Fuel Tank Draining Procedure (2-Door Utility). 3. Remove the fuel filler pipe. 4. Wipe the vent hose connection at the fuel tank and then disconnect the vent hose and clamp (1). 5. Wipe the fuel filler hose connection at the fuel tank and then disconnect the fuel filler hose and clamp (2). 6. Cap the fuel tank openings in order to prevent possible fuel system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel tank openings. 2. Install the fuel fill and vent hoses to the fuel tank. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the vent hose clamp (1) to 1.7 N.m (15 lb in). - Tighten the fuel fill hose clamp (2) to 2.5 N.m (22 lb in). Page 9413 Abbreviations And Meanings - Part 26 Page 4786 Page 8597 1. Install the seat back to the lower frame. 2. Install the seat back pivot bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat back pivot bolt to 47 N.m (35 lb ft). 3. Install the recliner assembly. 4. Install the seat to the vehicle. Seat Back Replacement - Front (Bucket Seat) SEAT BACK REPLACEMENT - FRONT (BUCKET SEAT) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the seat back cover and pad. 3. Remove the seat cushion trim cover and pad. 4. Disconnect the electrical connector for the seat back recliner motor, if equipped. 5. Remove the bolts securing the seat back to the seat adjuster assembly. 6. Remove the seat back. INSTALLATION PROCEDURE 1. Install the seat back to the seat adjuster assembly. 2. Install the bolts securing the seat back to the seat adjuster assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 719 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the electrical connector from the sensor. 4. Remove the bolt (2). 5. Using a twisting and pulling motion, remove the vehicle speed sensor (1) from the case. 6. Remove and discard the O-ring seal (3). Installation Procedure 1. Install the new O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with clean transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Remove the drain pan. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 4474 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 9456 Diagrams Door Lock And Window Switch - Front Passenger C2 Page 1305 2. Install the spare tire carrier washers and the mounting bolts. Tighten the spare tire carrier mounting bolts to 30 Nm (22 ft. lbs.). 3. Install the spare tire to the spare tire carrier. 4. Install the spare tire to the spare tire carrier mounting nuts. Tighten the spare tire to the spare tire carrier mounting nuts to 100 Nm (74 ft. lbs.). Important: Close the carrier assembly firmly enough to engage both latches, or the spare tire carrier will rattle when the vehicle is in motion. 5. Close the spare tire carrier. Page 2011 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 3765 11. If the vehicle is equipped with a 2.2L engine, install the bolt securing the dipstick to the exhaust manifold. 12. Install the bolts securing the oil level indicator tube to the engine. ^ Tighten the bolts to 47 Nm (35 ft. lbs.). 13. Install the transmission oil level indicator. 14. Fill the transmission to the proper level with DEXRON III transmission fluid. Page 1304 Spare Tire: Service and Repair Spare Tire Carrier Replacement (2 Door 4WD Utility) Spare Tire Carrier Replacement (2 Door 4WD Utility) Removal Procedure 1. Remove the spare tire from the spare tire carrier mounting nuts. 2. Remove the spare tire from the spare tire carrier. 3. Open the spare tire carrier. 4. Remove the spare tire carrier mounting bolts and the washers. 5. Remove the spare tire carrier from the vehicle. Installation Procedure 1. Install the spare tire carrier to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Page 7675 Abbreviations And Meanings - Part 3 Page 7306 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 7300 Abbreviations And Meanings - Part 26 Page 2719 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications SYMPTOMS - DATA LINK COMMUNICATIONS IMPORTANT: The following steps must be completed before using the symptom tables: 1. Perform the diagnostic system check for the subsystem exhibiting the symptoms. The subsystem diagnostic system check will identify where to begin diagnosis of the data link communication system. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/physical Inspection Inspect for aftermarket devices that could affect the operation of the serial data communications systems. - Inspect the easily accessible systems or visible system components for obvious damage or conditions that can cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS - The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. - When the class 2 serial data circuit: is shorted to ground - is shorted to voltage The following DTCs may set: U1300 - U1301 - U1305 TEST DESCRIPTION Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 4514 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear brake pads. 4. Remove the anti raffle retainers. 5. Remove the rear brake caliper bracket mounting bolts. 6. Remove the rear brake caliper bracket. Installation Procedure Page 5007 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 9649 Registered And Non-Registered Trademarks - Part 3 Page 6853 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. Page 3187 Steps 12-15 Page 3959 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 512 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Disconnect the fuel tank pressure sensor electrical connector. 6. Remove the fuel tank pressure sensor (1) from fuel sender assembly (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) on the fuel sender assembly (2). 2. Connect the fuel tank pressure sensor electrical connector. 3. Install the fuel tank. 4. Refill the fuel tank. 5. Install the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 4929 Registered And Non-Registered Trademarks - Part 2 Page 3804 Page 4685 Locations View Page 3358 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector (3). 2. Remove 2 screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 3. Remove the ignition control module and heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the 2 screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). Page 6059 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 187 Engine Control Module: Description and Operation Vehicle/Powertrain Control Module & the BCM VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(tm) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 8087 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 8341 WA810K/48 - WA812K/88 Page 8707 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 9518 Abbreviations And Meanings - Part 14 Page 4559 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Rear Brake Rotor Replacement - Rear Tools Required ^ J42450-A Wheel Hub Resurfacing Kit Removal Procedure Notice: Refer to Brake Caliper Notice in Service Precautions. Important: Do not disconnect the brake hose from the caliper. 1. Remove the brake caliper. 2. Remove the brake pads. Page 658 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove off road skid plate, if equipped. 3. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 4. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. 5. Drill out the mounting rivets. 6. Remove the inflatable restraint front end discriminating sensor from the vehicle. Page 3068 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Page 6817 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Page 6067 Arrows And Symbols Uses various symbols in order to describe different service operations Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 643 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 1643 6. Remove the bolts for the engine mount frame bracket. 7. Remove the engine mount frame bracket. 8. Remove the bolts holding the engine mount to the engine. 9. Remove the engine mount with the shield. Installation Procedure 1. Sub-assemble the engine mount, shield, and one bolt. Service and Repair Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Remove the bolts that retain the liftgate striker to the vehicle. 3. Remove the liftgate striker backing plate. 4. Remove the liftgate striker and any spacers from the vehicle. Installation Procedure 1. Install the liftgate striker. 2. Install any spacers to the vehicle. 3. Install the liftgate striker backing plate. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolts that retain the liftgate striker to the vehicle. Tighten the bolts to 22 N.m (16 lb ft). Page 5906 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut, increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage D Height Measurement The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle D heights should be within 18 mm (0.71 inch) for utilities and 30 mm (1.18 inch) for pickups without options QZ8 and V4A to be considered correct. Pickups with options QZ8 and V4A should be 0 mm to be considered correct 1. Place hand on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 3. Allow the vehicle to settle into position. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. 4. Measure the D height by measuring the distance between the rear axle tube or rear axle bracket on vehicles with 7300 GVW rating and the frame. 5. Repeat the jouncing operation 2 more times for a total of 3 times. 6. Use the highest and lowest measurements to calculate the average height. 7. The true D height dimension is the average of the highest and the lowest measurements. 8. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear leaf springs ^ Worn rear suspension components, such as leaf spring bushings. ^ Collision damage Page 3099 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 SYSTEM DESCRIPTION The scan tool is first used to energize the fuel pump relay. The scan tool is then used to pulse each injector for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-3 Page 8654 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 3818 9. Lower the transmission to gain access to the bolt securing the filler tube to the transmission torque converter housing. 10. Remove the bolt securing the filler tube to the torque converter housing. 11. Remove the filler tube and seal from the vehicle. Installation Procedure 1. Install a new seal into the transmission case. 2. Lubricate the seal with transmission fluid and install the filler tube into the seal. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt securing the filler tube to the transmission torque converter housing. ^ Tighten the bolt to 47 Nm (35 ft. lbs.). 4. Raise the transmission. 5. Install the transmission support. 6. Remove the transmission jack. Page 9462 Page 6554 2. Install the molding to the quarter panel rear window (4-Door only). 3. Install the molding fasteners to the quarter panel rear window (4-Door only). 4. Install the body side stationary window (2-Door only). NV 1500 Transmission Speed Sensor: Service and Repair NV 1500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the vehicle speed sensor electrical connector. 3. Remove the vehicle speed sensor retaining bolt. 4. Remove the vehicle speed sensor. Installation Procedure 1. Install the new O-ring seal to the vehicle speed sensor. 2. Coat the new O-ring seal with a thin film of transmission fluid. 3. Install the vehicle speed sensor Notice: Refer to Fastener Notice in Service Precautions. 4. Install the vehicle speed sensor retaining bolt. ^ Tighten the vehicle speed sensor retaining bolt to 16 Nm (12 ft. lbs.). 5. Connect the vehicle speed sensor electrical connector. 6. Lower the vehicle. Page 1122 Fluid - M/T: Service and Repair NV 3500 Fluid Replacement ^ Tools Required J36511 Oil Fill/Drain Plug Hex Bit Removal Procedure 1. Raise and support the vehicle. 2. Using J 36511 remove the oil fill and drain plugs. Drain the oil in a suitable container. Installation Procedure 1. Apply sealant to the oil drain plug threads. Use sealant GM P/N 12346004 or the equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 36511 install the oil drain plug. ^ Tighten the oil drain plug to 30 Nm (22 ft. lbs.). Page 9109 Equivalent - Decimal And Metric Part 1 Page 224 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(tm) sensor is inside the upper right side of the steering column. The Passlock(tm) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(tm) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(tm) sensor in order to help prevent tamper to the system. Passlock(tm) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(tm) sensor will generate a unique Passlock(tm) code. All 10 combinations of the Passlock(tm) sensor have the same part number. However, you cannot simply replace the Passlock(tm) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Sunroof - Water Leaks Into The Interior Sunroof / Moonroof Drain: All Technical Service Bulletins Sunroof - Water Leaks Into The Interior Bulletin No.: 03-08-57-005 Date: November 19, 2003 TECHNICAL Subject: Water Found In Rear Cupholder or On Floor of Vehicle (Reroute Rear Sunroof Drain Hose) Models: 2003-2004 Chevrolet Blazer (2-Door) 2003-2004 GMC Jimmy (2-Door) (Canada only) Built Prior to VIN Breakpoint 4K124402 Condition Some customers may comment on water in the rear trim panel cupholder or on the rear floor. Cause Important: Do not remove the energy absorbent foam from the headliner. It is a government requirement. Due to energy absorbent foam in the headliner, the hose runs upward and the water cannot drain. Correction Reroute the left and right rear sunroof drain hoses. 1. Fold the rear seats down. 2. Remove the front and rear upper seat belt anchor bolt. 3. Remove the assist handles. 4. Remove the coat hooks. 5. Remove the end gate sill plate. 6. Remove the rear upper garnish molding and unplug the connector for the cargo lamp. 7. Remove the spare tire and holder if the tire is inside the vehicle. 8. Remove the jack storage cover and the jack. 9. Remove the screw that retains the upper trim (left side only). Diagrams Automatic Transmission Shift Lever Position Indicator Page 7670 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 2905 Manifold Absolute Pressure (MAP) Sensor Page 5253 C203 (Body Harness To IP Harness) Part 8 Page 9154 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 8653 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 8429 3. Install the tap plates in the cross rails. 4. Install the cross rails on to the sliders. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the screws to the cross rails. Tighten the screws to 1.9 N.m (17 lb in). 6. Install the side rail supports to the side rails. 7. Install the screws to the side rail supports. Tighten the screws to 1.9 N.m (17 lb in). 8. With an assistant, install the luggage carrier as an assembly onto the roof. 9. Install the end support to the roof screws. Tighten the screws to 2.8 N.m (25 lb in). 10. Install the rubber strips to the cross bar assemblies. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 5976 1. Install the power steering gear pressure hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering gear pressure hose to the power steering gear. Tighten the power steering gear pressure hose to the power steering gear to 30 Nm (22 ft. lbs.). 3. Install the air cleaner assembly. 4. Raise the vehicle. 5. Connect the power steering gear pressure hose to the power steering pump. Tighten the power steering gear pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). 6. Remove the drain pan from under the vehicle. 7. Install the steering linkage shield, if equipped. 8. Lower the vehicle. 9. Bleed the power steering system. Page 3775 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 9555 Heated Glass Element: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS HVAC CONTROL MODULE Rear Defog Switch: The scan tool displays On or Off. When the rear defogger switch is pressed, the scan tool will display On. When the switch is released, the scan tool displays Off. HVAC Control Module HVAC Control Module Page 6325 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 6581 Compressor Clutch Coil: Service and Repair Installation With RPO Code HT6/HD6/HU6 COMPRESSOR CLUTCH COIL INSTALL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED - J 33024 Clutch Coil Installer Adapter - J 8433-1 Puller Bar - J 8433-3 Forcing Screw - J 34992 Compressor Holding Fixture - J 33017 Pulley and Bearing Installer - J 33023-A Puller Pilot - J 6083 External Snap Ring Pliers 1. Place the clutch coil assembly (1) on the front head. Position the terminals at the marked location. 2. Place the J 33024 over the internal opening of the clutch coil housing. 3. Align the J 33024 with the compressor front head. 4. Center the J 8433-1 in the counter-sunk center hole of the J 33024. 5. Install the 2 through bolts and washers through the crossbar slots. 6. Thread the bolts into the J 34992 in order to achieve full fixture thickness. 7. Turn the center forcing screw of the J 8433-1 in order to force the clutch coil onto the front head. Ensure that the clutch coil and the J 33024 remain aligned during installation. 8. When the coil is fully seated on the front head, use a 1/8 inch diameter drift punch (2) in order to stake the front head at 3 places 120 degrees apart (3), in order to ensure that the clutch coil (1) remains in position. Page 6373 The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Page 9362 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8742 Seat Rear Vertical Position Sensor - Driver (w/ Memory) Page 1626 Drive Belt Squeal Diagnosis Step 1 - 9 Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 1 Page 1321 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 9414 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Description and Operation Air Bag Deactivation Indicator: Description and Operation INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH INDICATOR The instrument panel (I/P) module disable switch ON/OFF indicator is an LED located in a position that can been viewed by the occupants in the front seats. The location varies depending on the vehicle. When the I/P module disable switch is in the disable position, the I/P module disable switch indicator illuminates. When the I/P module disable switch is in the enable position, the I/P module disable switch indicator is not illuminated. The I/P module disable switch indicator will dim to a lower intensity when the headlamp switch is turned ON. Page 8110 Console: Service and Repair Console Replacement - Front Floor (Full-Length (Manual Trans) Console Replacement - Front Floor (Full Length (Manual Trans)) Removal Procedure 1. Remove the shift control lever. 2. Remove the cup holder insert. 3. Remove the screws that retain the trim plate to the console. 4. Remove the trim plate from the console. 5. Open the storage compartment cover. 6. Remove the storage compartment. 7. Remove the nuts that retain the console to the vehicle. 8. Disconnect the electrical connector, if equipped. 9. Remove the console from the vehicle. Installation Procedure 1. Install the console to the vehicle. 2. Connect the electrical connector, if equipped. Locations SIR Components Page 1930 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8 - 11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8 - 11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 5332 C211 (Steering Column Harness To Body Harness) Part 4 Page 4675 Brake Hose/Line: Service and Repair Tube Adapter Replacement Tube Adapter Replacement Removal Procedure Important: If you must remove more than one tube adapter at one time, stamp the BPMV with a number (1, 2 or 3) in order to indicate the number of grooves cut into the tube adapters. This procedure will aid proper reassembly. 1. Remove the appropriate brake line from the tube adapter (1). 2. Remove the tube adapter from the BPMV (3). Installation Procedure 1. Install the new gasket (2) on the tube adapter (1). Notice: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the new tube adapter (1) into the BPMV (3). Tighten the tube adapter to 31 Nm (23 ft. lbs.). 3. Install the brake line. Tighten the brake line to 29 Nm (22 ft. lbs.). 4. Bleed the system. Page 4699 Wheel Cylinder: Specifications Wheel Cylinder Mounting Bolts 13 ft. lbs. Bleeder Valve 62 inch lbs. Page 5799 Splice Pack SP204 Part 3 Splice Pack SP401 Page 9110 Equivalent - Decimal And Metric Part 2 Page 2078 Engine, LR Page 3332 4. Install the ignition coil wire. The wire must not touch anything like the dip stick. Rubbing will make a ground or short after time of use. 5. Install the electrical connectors. 6. Install the air cleaner assembly (2) and nut (1). Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 188 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the powertrain control module (PCM) or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing/replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Move the PCM retention bar and retainer away from the PCM. 3. Remove the PCM from the PCM mounting bracket. Page 3796 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 7040 For vehicles repaired under warranty, use the table. Disclaimer Page 8874 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Inner Removal Procedure 1. Remove the side front door trim panel. 2. Remove the staples that secure the sealing strip to the trim panel. 3. Remove the sealing strip. Installation Procedure 1. Position the sealing strip on the trim panel. 2. Install the sealing strip to the trim panel using the original staples or a heavy-duty staple gun. 3. Install the side front door trim panel. Page 180 Powertrain Control Module (PCM) Connector C2 Part 2 Page 4503 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol. 2. Dry the brake caliper pin bolts using non lubricated, compressed filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper bolts. 4. DO NOT apply the lubricant to the brake pad hardware. 5. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the brake caliper bolts. Tighten the brake caliper bolts to 31 Nm (23 ft. lbs.). Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate window latch support. 2. Disconnect the electrical connectors, as needed. 3. Remove the clip that retains the liftgate lock cylinder to the liftgate. 4. Remove the liftgate lock cylinder from the liftgate. Installation Procedure 1. Install the liftgate lock cylinder to the liftgate. 2. Install the clip that retains the liftgate lock cylinder to the liftgate. 3. Connect the electrical connectors, as needed. 4. Install the liftgate window latch support. Page 2691 Abbreviations And Meanings - Part 11 Page 9781 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 3218 2. Install the throttle body assembly with a new seal. 3. Install the throttle body assembly retaining studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 9 N.m (80 lb in). 4. Install the accelerator control cable bracket using the mounting stud and nuts. Tighten Tighten the stud and nuts to 12 N.m (106 lb in). Page 312 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Page 1359 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 4430 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 3602 ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 380 A/C High Pressure Switch Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Remove the body side stationary window (2-Door only). 2. Remove the molding from the quarter panel rear window (4-Door only). 3. Remove the pressure relief ventilation valve using a flat-bladed tool in order to release the retainers. Installation Procedure 1. Install the pressure relief ventilation valve assembly pressing into place until firmly seated. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 7146 Driver Information System Diagram 3 Page 7484 Speaker - LR (2-Door Utility) Page 4734 Parking Brake Lever: Service and Repair Park Brake Release Handle Assembly Replacement Removal Procedure 1. Release the park brake, if applied. 2. Remove the knee bolster trim panel. 3. Remove the brake release handle from the park brake pedal. Installation Procedure 1. Install the brake release handle. Page 3366 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Service Precautions Vehicle Lifting: Service Precautions CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Page 6517 Abbreviations And Meanings - Part 18 Page 3524 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Page 7008 Disclaimer Page 2712 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 5381 Splice Pack SP203 Part 1 Page 557 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 4266 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 2635 Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 3165 Fuel Filler Hose: Service and Repair Filler Tube Replacement (4-Door Lower) REMOVAL PROCEDURE 1. Drain the fuel from the fuel tank, leaving the lower fuel fill hose disconnected. 2. Remove the spare tire (underbody mounted spare tire only). 3. Loosen the upper fuel fill hose clamp (7). 4. Disconnect the ground wire (5) from the frame crossover. 5. Remove the ground wire retaining straps (6) from the lower fuel fill tube. 6. Remove the lower fuel fill tube retaining bolt from the frame crossover. Page 8378 WA765J/37 - WA800J/98 A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 4722 8. Using a screwdriver (1), adjust the rear brake shoes (2). 9. Adjust the park brakes. 10. Lower the vehicle. Refer to Vehicle Lifting. Page 1707 5. Install new seals on the engine oil cooler lines. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolt attaching the engine oil cooler lines to the engine oil filter adapter. Tighten the engine oil filter adapter bolt to 35 Nm (26 ft. lbs.). 7. Install the cooler line clamp and the bolt. Tighten the cooler line clamp bolt to 10 Nm (89 inch lbs.). 8. Lower the vehicle. 9. Inspect and fill the engine oil to the proper level. Page 554 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 7276 Abbreviations And Meanings - Part 2 Page 1029 2. For a RWD vehicle, install the oil filter to the oil filter adapter. 3. For Four-Wheel Drive vehicles, install the oil filter to the remote oil filter adapter. 4. Tighten the oil filter following the instructions on the filter. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan drain plug into the oil pan. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the crankcase with the proper capacity and quality of engine oil. 8. Operate the engine and check for leaks and oil pressure. 9. For a Four-Wheel Drive vehicles, close the access panel in the steering linkage shield. Page 7735 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry, any door opened, the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch, door jamb switch - Passenger door latch, door jamb switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(tm) data from the Passlock(tm) sensor. If the Passlock(tm) data is correct, the BCM will pass theft. The BCM will then transmit the code password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(tm) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(tm) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Page 4968 Page 3210 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 4024 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 2988 Rear Frame (4-Door) Page 4921 Abbreviations And Meanings - Part 21 Page 8146 Drink Holders: Removal and Replacement Cupholder Replacement - Front Floor Console Cupholder Replacement - Front Floor Console Removal Procedure Pull up on the lower edges of the cup holder in order to release the retaining clips and remove the cup holder from the vehicle. Installation Procedure Install the front floor cup holder to the vehicle. Cupholder Replacement - Front Seat Cupholder Replacement - Front Seat Removal Procedure 1. Press the retaining tab under the cupholder while pulling outward in order to remove the cupholder from the bracket. 2. Remove the rubber pad. Installation Procedure NV 1500 Vehicle Speed Sensor Page 4977 Starter Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Specifications Parking Brake Cable: Specifications Park Brake Cable Mounting Bracket Bolt 12.6 ft. lbs. Page 5677 C211 (Steering Column Harness To Body Harness) Part 2 Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Mark, sort, and organize all the components for assembly. 2. Remove the valve rocker arms. 3. Remove the valve rocker arm supports. 4. Remove the valve pushrods. Important: Parts that are to be reused must be marked, sorted, and organized for assembly. 5. Mark, sort, and organize the components for assembly. Page 6689 17. Install the HVAC module mounting nut located at the lower right side of the heater core to heater connection. Tighten Tighten the HVAC module mounting nut to ..............4.5 N.m (40 lb in). 18. Install the HVAC module mounting bolt located at the lower left side of the heater core to heater hose connection. Tighten Tighten the HVAC module mounting bolt to.............. 4.5 N.m (40 lb in). 19. On vehicles with the 2.2 L engine only, install the engine wiring harness bracket located at the rear of the intake manifold. 20. Install the HVAC module mounting bolt through the blower motor resistor or service access cover opening. IMPORTANT Use the same mounting bolt marked during removal for the HVAC module during the installation process. Other mounting bolts are longer and will obstruct the operation of the temperature door. Tighten Tighten the HVAC module mounting bolt to .........4.5 N.m (40 lb in). 21. Install the blower motor resistor. 22. Refill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 23. Install the instrument panel. Page 2245 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Page 4782 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Remove the fluid level sensor (1). Use a needle nose pliers in order to compress the locking tabs at the opposite side of the master cylinder. Installation Procedure 1. Install the fluid level sensor (1) until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Page 9619 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 6315 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. - After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 5171 Fuse Block - Underhood Connector C1 Part 2 Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 6956 Disclaimer Page 7705 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Controls Switch - Left Page 5855 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 5110 Abbreviations And Meanings - Part 3 Page 1175 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 9799 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 5519 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5356 C411 (Body Harness To Endgate Harness) Page 5888 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 5995 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the air cleaner assembly. 3. Remove the power steering pump pulley. 4. Disconnect the power steering pressure hose from the power steering gear. 5. Disconnect the power steering cooler hose from the power steering pump. 6. Disconnect the air reactor tube from the lower reactor tube. 7. Remove the air reactor pipe lower retaining nut. 8. Disconnect the air reactor pipe from the check valve and remove reactor pipe. Page 6803 Inflatable Restraint Steering Wheel Module Coil C3 (Pigtail To The SWC Switches) Page 8664 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 8100 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: Page 779 Equivalent - Decimal And Metric Part 2 Page 4483 ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the piston is fully seated in the brake caliper bore. ^ Remove the C-clamp from the caliper. 7. Remove the brake caliper hose bolt from the brake caliper. 8. Remove the 2 metal gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 9. Discard the 2 metal gaskets. 10. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 11. Remove the brake caliper mounting bolts. 12. Remove the brake caliper. 13. Remove the brake pads from the brake caliper. 14. Remove the brake caliper mounting bolt sleeves. 15. Remove the rubber O-rings. Hood Latch Replacement - Primary Hood Latch: Service and Repair Hood Latch Replacement - Primary Hood Latch Replacement - Primary Removal Procedure 1. Raise and support the hood. 2. Remove the hood release cable from the primary hood latch: 1. Place a flat-bladed tool into the cable clip. 2. Pry the cable clip open in order to remove the cable. 3. Pry the cable housing from the primary latch. 3. Mark the mounting bracket position. 4. Remove the bolts that retain the primary latch mounting bracket to the radiator support. 5. Remove the primary hood latch and mounting bracket from the vehicle. 6. Remove the bolts that retain the primary hood latch to the mounting bracket. 7. Remove the primary hood latch from the mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 4487 9. Remove the brake caliper assembly. Installation Procedure 1. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake caliper bolts to the mounting bracket. Tighten the brake caliper bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Installing Hoses without Twists or Bends Notice in Service Precautions. Important: When performing the following service procedure, DO NOT reuse the old bolt washers. Always use new washers. Page 5296 Multiple Junction Connector: Diagrams C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 1 Engine - Balance Shaft Rattling Noises (Cancellation) Balance Shaft: Technical Service Bulletins Engine - Balance Shaft Rattling Noises (Cancellation) Bulletin No.: 00-06-01-023C Date: August 30, 2006 TECHNICAL Subject: Engine/Balance Shaft "Rattle" Noise Models: 1992-2003 Chevrolet and GMC C/K, S/T, M/L, G and P Models 1992-2001 Oldsmobile Bravada with 4.3 L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to cancel this bulletin. Please discard Corporate Bulletin Number 00-06-01-023B (Section 06 -- Engine/Propulsion System). Technicians should refer to Corporate Bulletin Number 03-06-01-024C for information on engine/balance shaft "rattle" noise concerns. Disclaimer Page 5528 Abbreviations And Meanings - Part 7 Page 2070 1. Install the radiator inlet hose to the coolant outlet. 2. Using the J 38185, reposition the radiator inlet hose clamp to the coolant outlet. 3. Install the radiator inlet hose to the radiator. 4. Using the J 38185, reposition the radiator inlet hose clamp to the radiator. 5. Install the radiator inlet hose to the radiator support. 6. Install the air cleaner outlet duct. 7. Fill the cooling system. 8. Inspect the cooling system for leaks. Page 9771 Page 1711 Oil Line: Service and Repair Remote Oil Filter Adapter Pipe Replacement Remote Oil Filter Adapter Pipe Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the steering linkage shield, if equipped. 3. Position a suitable drain pan for the engine oil to drain into when the hoses are removed. 4. Remove the remote oil filter inlet and outlet hose clip bolt from the oil pan. 5. Remove the bolt attaching the remote oil filter inlet and outlet hoses to the remote oil filter adapter. 6. Remove the remote oil filter inlet and outlet hoses and the seals from the remote oil filter adapter. 7. Discard the remote oil filter inlet and outlet hose seals. 8. Remove the bolt attaching the remote oil filter inlet and outlet hoses to the oil filter pipe adapter. 9. Remove the remote oil filter inlet and outlet hoses. 10. Remove and discard the remote oil filter inlet and outlet hose seals. 11. Clean and inspect the remote engine oil filter inlet and outlet hoses and fittings. Installation Procedure Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Diagrams Passlock Sensor Page 1911 10. Remove the mounting clamp hold down bolt. 11. Remove the distributor. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than 1 clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving proper rotor alignment during the distributor installation. INSTALLATION PROCEDURE 1 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the 2 marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). Page 8553 Seat Recliner Motor - Driver (w/o Memory) OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 8853 4. Install the 1 screw in order to secure the step panel inboard tab to the pickup box rear inner pillar. Tighten Tighten the inboard tab screw to 1.5 N.m (13.3 lb in). 5. Install the forward brace to the forward support bracket using the 1 screw. Tighten Tighten the forward brace to forward support bracket screw to 9.0 N.m (6.6 lb ft). 6. Install the forward brace to the step panel using the 1 screw. Tighten Tighten the screw to 9.0 N.m (80 lb in). Page 4085 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4688 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco, Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. Page 2031 Fan Shroud: Specifications Fan Shroud Bolts ................................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Page 1847 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 5259 C209 (Dome Harness To Body Harness) Part 2 Page 21 For vehicles repaired under warranty use, the table. Disclaimer Page 5011 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 5347 C306 (Body Harness To RR Door Harness) (4-Door) Page 753 Specifications Brake Shoe: Specifications Above rivet head or backing plate. Minimum Thickness 0.030 inch Page 5513 Conversion English/Metric Part 2 Page 9695 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 4488 3. Install the brake hose bolt and washers. Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 4. Fill the brake master cylinder to the proper level. 5. Bleed the brake calipers. 6. Install the tire and wheel assembly, 7. Lower the vehicle. Refer to Vehicle Lifting. Locations Seat Harness Routing (8-Way w/o Memory) Page 1496 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve rocker arm assemblies as follows: 4.1. Finger start the bolt at location (1). 4.2. Finger start the bolt at location (2). 4.3. Finger start the bolt at location (3). 4.4. Finger start the remaining valve rocker arm bolts. 5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57 - 63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the valve rocker arm bolts Tighten valve rocker arm bolts to 30 Nm (22 ft. lbs.). 7. Install the valve rocker arm cover. Page 9498 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement ^ Tools Required J 23742 Ball Joint Separator - J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer Removal Procedure Caution: Refer to Floor Jack Caution in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. ^ Support the lower control arm with floor stands. ^ Place floor stands under the lower control arms as far outboard as possible (between spring seats and ball joint) to maintain maximum leverage. 2. Remove the rotor. 3. Remove the bolts that attach the splash shield to the steering knuckle. Page 3894 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Sunroof Opening Position Switch Replacement Sunroof / Moonroof Switch: Service and Repair Sunroof Opening Position Switch Replacement SUNROOF OPENING POSITION SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Move the sunroof to the closed position. IMPORTANT: Remove the headliner. - The sunroof open position (SOP) switch is aligned to the drive cables. The SOP switch comes from the factory set to the sunroof glass panel CLOSED position. A position lock pin has been installed by the factory on the top of the SOP switch. This pin must remain until after the installation of the sunroof actuator and of the SOP switch. This lock pin locks the drive gears in place and must be removed before the complete sunroof module is installed to the vehicle. - If the SOP switch is removed for inspection, the sunroof must be in the CLOSED position. A position lock pin must be inserted. If a position lock pin is not available, place 2 wires, such as the ends of a paper clip, in the holes. 1. Remove the sunroof window. 2. Remove the sunroof control module. 3. If you reuse the SOP switch, insert the position lock pin (1) in order to lock the SOP switch in the closed position. 4. Remove the sunroof motor/actuator. 5. Disconnect the electrical connector from the SOP switch (3). 6. Remove the screw (2) which secures the SOP switch to the sunroof module. 7. Hold down on both of the drive cables. Lift up on the SOP switch in order to remove the switch from the sunroof module. INSTALLATION PROCEDURE 1. Use a flat-bladed tool if you adjust the cable mechanism and/or the cam mechanism in order to align the cable and/or the cam timing holes. IMPORTANT: The cable mechanisms and/or the cam mechanisms, on both sides of the glass, contain a set of timing holes. These holes are aligned in the CLOSED position of the sunroof glass panel . These holes are located on the side opposite the rear screw hole, which is used in order to mount the sunroof glass panel. When installing a new sunroof open position (SOP) switch, set the sunroof glass panel to the CLOSED position. When the timing holes are aligned, insert a pin with diameter 0.0317 mm (1/8 in) or a drill bit (1) into each set of the timing holes. Use tape in order to hold each pin in place. Page 6182 9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time. 10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position. 11. Remove the balance shaft drive gear. Page 2567 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Page 6338 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Locations LF Front Fender Area Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 5692 C304 (Body Harness To LR Door Harness) (4-Door) Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Page 6469 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 8376 WA711J/58 - WA722J/25 Page 5294 C432 (Body Harness To Defogger Grid Harness) Page 9196 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. NV 1500 Seals and Gaskets: Service and Repair NV 1500 Transmission Housing Oil Seal Replacement (Rear) Transmission Housing Oil Seal Replacement (Rear) ^ Tools Required J. 23129 Universal Seal Remover - J 6125-1B Slide Hammer - J 36503 Seal Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the rear propeller shaft 3. Remove the rear oil seal from the rear case using the J6125-1B (1) and the J23129 (2). 4. Remove the rear oil seal from the extension housing. Installation Procedure 1. Using the J 36503 install the new rear oil seal. 2. Install the rear propeller shaft. 3. Fill the transmission to the proper fluid level. 4. Lower the vehicle. Transmission Housing Oil Seal Replacement (Front) Transmission Housing Oil Seal Replacement (Front) ^ Tools Required J 41371 Reluctor Gear Puller - J 38801 Input Shaft Seal Installer Page 9526 Abbreviations And Meanings - Part 22 Page 6659 6. Open the heater inlet hose retaining clip above the right side valve cover. Use a flat bladed tool to open the clip from the bottom. 7. Remove the heater inlet hose from the vehicle. INSTALLATION PROCEDURE 1. Apply lubricant, GM P/N 9985662, to each end of the heater inlet hose. 2. Install the heater inlet hose to the vehicle. IMPORTANT:When installing new heater inlet hose, place the clamp on the hose before installing the hose to the vehicle. 3. Install the heater inlet hose to the intake manifold fitting. 4. Install the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Install the heater inlet hose to the heater core. 6. Install the heater inlet hose clamp using the J 38185 at the heater core. Page 2471 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ....................................................... ACDelco 41-948 Page 4546 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 3102 Steps 6-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Page 5196 Relay Block - Body Part 6 Page 6478 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 3712 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 6075 English Prevailing Torque Fastener Minimum Torque Development Part 1 A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 2354 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 5686 Multiple Junction Connector: Diagrams C300 - C317 C300 (Dome Lamp Harness To Sunroof Harness) Page 8395 WA9260/74 - WA9260/74 Page 5791 Splice Pack SP200 Part 2 Page 9139 Abbreviations And Meanings - Part 17 Page 3577 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Locations Door Wiring Harness (RR Shown, LR Similar) Page 8571 Seat Adjuster Switch - Driver C2 (w/ 8-Way, w/o Memory) Page 5318 C203 (Body Harness To IP Harness) Part 6 Page 5238 C108 - Electric Shift Transfer Case Extension Harness To Body Harness, NP1 Page 8960 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 9149 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 7487 Speaker - RF Door Page 6417 INSTALLATION PROCEDURE 1. Install the accumulator into the accumulator clamp. IMPORTANT If replacing the accumulator, add the refrigerant oil to the accumulator. Refer to Refrigerant System Capacities for system capacity information. 2. Install the accumulator clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the bolt to 10 N.m (88 lb in). 3. Install the A/C low pressure switch. 4. Install new O-ring seals. 5. Connect the compressor hose assembly to the accumulator (2). Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the accumulator to evaporator retaining nut. Tighten Tighten the nut to28 N.m (21 lb ft). 7. Connect the electrical connector to the A/C pressure switch (4.3L only). Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement ^ Tools Required J 35621-B Rear Main Seal Installer Removal Procedure 1. Remove the transmission assembly. 2. Remove the engine flywheel. 3. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing. 4. Discard the crankshaft rear oil seal. 5. Clean off any dirt or rust in the area. Installation Procedure 1. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing. 2. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange. 3. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin. 4. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface. 5. Inspect the J 35621-B flange for imperfections that may damage the crankshaft rear oil seal. Minor imperfections may be removed with a fine grade emery cloth. Important: DO NOT allow oil or any other lubricants to contact the seal lip surface of the crankshaft rear oil seal. 6. Remove the sleeve from the crankshaft rear oil seal. 7. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal. 8. Install the crankshaft rear oil seal onto the J 35621-B. 9. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 2282 Heated Oxygen Sensor (HO2S), Bank 2 Sensor 1 Electronic Components Electronic Components Page 413 3. Install the electrical connector. 4. Install the knee bolster trim panel. Page 767 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 1751 ^ The A/C clutch switch, if equipped (1) ^ The Engine Coolant Temperature (ECT) sensor (4) 16. Remove the engine wiring harness clips from the brackets. 17. Move the engine wiring harness aside. 18. Remove the accelerator cable bracket from the throttle body and the intake manifold. 19. Remove the accelerator and the cruise control cable bracket from the throttle bracket. Leave the accelerator and cruise control cables on the bracket. 20. Disconnect the PCV hose assembly from the intake manifold and the valve rocker arm cover. 21. Remove the Evaporative Emission (EVAP) canister purge solenoid valve. 22. Remove the distributor. 23. Disconnect the fuel supply and return pipes at the rear of the intake manifold. Page 3916 9. Install the range selector cable end (2) to the range selector lever ball stud (1). 10. Depress the locking tab of cable (1) to set the adjustment. 11. Install the positive assurance pin (2) into the bracket. 12. Lower the vehicle. 13. Check the vehicle for proper operation The following conditions must be met: ^ When moving the shift lever from Park to L, all detent positions will be attainable. ^ There will be an equal amount of "free play" between the shift lever and the gate in the drive and reverse detent. If there is no "free play", the adjustment is not acceptable. ^ With the key in the "on" position and shift lever in reverse, the key will not be removable, and the steering wheel will not be locked. ^ With the key in the "locked" position, and the shift lever in the "park" position, the key will be removable, the steering wheel will be locked, and the shift lever will not disengage park. Page 5348 C307 (Body Harness To RR Door Harness) (4-Door) Page 5840 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 9499 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating General Information Vehicle Lifting: Service and Repair General Information LIFTING AND JACKING THE VEHICLE CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 1045 8. Remove the heater outlet hose from the retaining clip at the engine water outlet. 9. Open the outlet heater hose retaining clip above the right side valve cover. Use a flat bladed tool to open the clip from the bottom. 10. Remove the outlet heater hose from the vehicle. INSTALLATION PROCEDURE 1. Apply lubricant, GM P/N 9985662, to each end of the outlet heater hose. 2. Install the outlet heater hose to the vehicle. IMPORTANT:When installing new outlet heater hose, place the clamp on the hose before installing the hose to the vehicle. Page 7286 Abbreviations And Meanings - Part 12 Page 3115 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 2. Using compressed air, blow any dirt out of the quick-connect fitting. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Squeeze the plastic retainer release tabs. 4. Pull the connection apart. INSTALLATION PROCEDURE Page 9669 Page 2131 Body Control Module (BCM) C2 Part 3 Page 7289 Abbreviations And Meanings - Part 15 Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 3. Remove the two screws from the rotor. 4. Remove the rotor. Page 3308 5. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 6. Line up the square-cut hole in the vane wheel with the camshaft position (CMP) sensor. 7. Remove the two screws that hold the CMP sensor. 8. Discard the screws. Page 6845 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 4407 Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the four EBCM bolts. Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM (2). 4. Install BPMV (3) to EHCU bracket (5). 5. Connect the two electrical harness connectors to the EBCM (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the BPMV (3). Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Bleed the brake system. Page 2265 Knock Sensor (KS) Page 7830 Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Door Bottom Sealing Strip Replacement - Door Bottom Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Use the J 38778 in order to remove the door bottom weatherstrip from the door. Installation Procedure 1. Position the door bottom weatherstrip. 2. Press the weatherstrip into place. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 5521 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 8759 Seat Lumbar Switch - Front Passenger Part 2 Page 5586 Fuse Block - Underhood Connector C1 Part 3 Page 462 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Specifications Steering Shaft: Specifications Lower Intermediate Shaft Coupling Bolt 26 ft. lbs. Page 4652 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot into the caliper housing bore by hand. 4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by hand. 5. Install the boot on the piston. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Removal Procedure Page 2990 Evaporative Emission (EVAP) Canister Vent Solenoid Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 1034 12. Install the A/C refrigerant filter (1) to the evaporator tube with the flow arrow pointing towards the evaporator. 13. Install the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the nuts to.................15 N.m (11 lb ft). 14. Remove the nuts (4) from the A/C refrigerant filter (1). 15. Coat the O-ring seals (3) with 525 viscosity refrigerant oil. 16. Install the O-rings (3) to the evaporator tube. 17. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to.........................15 N.m (11 lb ft). 18. Install accumulator (4) to the evaporator (3). 19. Tighten the accumulator nut at the evaporator. Tighten Tighten the nut to..........................15 N.m (11 lb ft). 20. Position the accumulator bracket 60 mm (2.36 in) toward the high side access port. 21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 22. Leak test the fittings component using the J 39400-A. 23. Install the engine coolant reservoir. 24. Install the PCM. Page 406 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille. 2. Lift the temperature sensor upward in order to remove the temperature sensor. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the temperature sensor by sliding the temperature sensor downward. 3. Install the radiator grille. Page 9199 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 4349 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 5590 Fuse Block - Underhood Connector C1 Part 7 Page 5379 Splice Pack SP201 Part 2 Page 2465 Distributor: Service and Repair Distributor Inspection 1. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 1.1. Remove the cap. 1.2. Place 1 lead from the DMM on a cap terminal. 1.3. Use the other lead in order to probe all other terminals and the center carbon ball. 1.4. Move the base lead to the next terminal. Probe all other leads. 1.5. Continue this procedure until you test all the secondary terminals. 1.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 3. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 4. Inspect the shaft for shaft-to-bushing looseness: 4.1. Inspect the housing for cracks or damage. 4.2. Insert the shaft in the housing. 4.3. If the shaft wobbles, replace the housing assembly. Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 3. Remove the two screws from the rotor. 4. Remove the rotor. Page 9576 Page 4713 6. Remove the retainer and the grommet. 7. Remove the front brake cable from the park brake pedal. 8. Remove the front park brake cable. Installation Procedure 1. Install the front park brake cable in the connector. Page 1103 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 2241 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 6809 IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. 5. Firmly seat the retaining ring (3) into the groove on the steering shaft assembly (2). 6. Remove and discard the centering tab from the new SIR coil (4). 7. Install the upper shroud (1) and secure by using 2 TORX(r) head screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). 8. Install the lower shroud (2) and secure by using 2 TORX(R) head screws (1). Page 7231 Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid and the EVAP canister. The service port is identified by a greencolored cap. Page 9365 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 2822 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 6199 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the rear axle. 3. Disconnect automatic level control air lines from shock absorber, if equipped. 4. Remove the shock absorber upper mounting bolts. 5. Remove the shock absorber lower mounting nut. 6. Remove the shock absorber lower mounting bolt dour door utilities only). 7. Remove the shock absorber from the vehicle. Installation Procedure 1. Install the shock absorber to the vehicle. 2. Install the shock absorber lower mounting bolt (four door utilities only). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shock absorber upper mounting bolts. Tighten the shock absorber upper mounting bolts to 25 Nm (18 ft. lbs.). 4. Install the shock absorber lower mounting nut. ^ Tighten the shock absorber lower mounting nut to 84 Nm (62 ft. lbs.) on pickups and 2-door utility models. ^ Tighten the shock absorber lower mounting nut to 100 Nm (74 ft. lbs.) on 4-door utility models. 5. Connect automatic level control air line to shock absorber, if equipped. 6. Remove the rear axle support. 7. Lower the vehicle. Page 2232 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 307 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Remove the fluid level sensor (1). Use a needle nose pliers in order to compress the locking tabs at the opposite side of the master cylinder. Installation Procedure 1. Install the fluid level sensor (1) until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Page 5457 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 87 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 4900 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 4896 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Service Precautions Hose/Line HVAC: Service Precautions CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED. MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Service and Repair Window Handle: Service and Repair Window Regulator Handle Replacement - Door Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Close the window. 2. Insert the J 9886-01 between the handle and the bearing plate. 3. Align the J 9886-01 with the handle. 4. Push the J 9886-01 in order to disengage the clip. 5. Pull the handle from the door. 6. Remove the window regulator handle from the door. 7. Remove the bearing plate from the door. Installation Procedure 1. Install the bearing plate to the door. Page 9099 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 7343 For vehicles repaired under warranty use, the table. Disclaimer Page 5010 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 5092 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 1834 Tighten the bolts to 12 N.m (106 lb in). Parts Information Warranty Information Page 2449 For vehicles repaired under warranty, use the table. Disclaimer Locations Sunroof Components (ZRX, Extreme W/ CF5) Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the radiator. 3. Remove the nut retaining the compressor hose to the condenser. 4. Remove the compressor hose assembly from the condenser. 5. Remove the evaporator tube from the condenser. 6. Remove the insulator retainer bolts and the upper insulator retainers. 7. Remove the condenser from the vehicle. INSTALLATION PROCEDURE 1. Install the condenser to the vehicle. IMPORTANT If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information. 2. Install the upper insulator retainers and the insulator retainer bolts. Page 8986 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 1768 30. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold. 31. Remove and discard the seal. 32. Remove the throttle body if replacing the upper intake manifold. 33. Remove the MAP sensor if replacing the upper intake manifold. Installation Procedure 1. Install the throttle body, if removed. 2. Install the MAP sensor, if removed. 3. Install the PCV valve cover, if removed, using the following procedure: 3.1. Install a NEW seal (O-ring) on the PCV valve cover. 3.2. Lubricate the seal with clean engine oil. 3.3. Install the PCV valve cover in the upper intake manifold. 3.4. Turn and lock the PCV valve cover in position. Page 8158 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Page 6374 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.03-0.13 mm (0.001-0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Page 3687 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1328 Disclaimer Page 1260 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 6582 9. Ensure that the stake size is only one-half the area of the punch tip. Ensure that the stake is only approximately 0.28-0.35 mm (0.010-0.015 in) deep. 10. With the compressor mounted to the J 34992, position the pulley rotor (1) and bearing assembly on the front head. 11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 12. Position the J 8433-1 on the J 33023-A. 13. Assemble the 2 through bolts and washers through the puller bar slots. 14. Thread the bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 15. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. If the J 33017 slips off direct in-line contact with the inner race and bearing, perform the following steps: 15.1. Loosen the J 8433-3. 15.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. Page 4056 Page 9767 Page 9157 Driver Information Center (DIC) C1 (w/o Trip Computer) Page 795 Abbreviations And Meanings - Part 4 Page 8117 rotated to fit over the shift handle. 3. Remove the passenger side toe-panel by gently prying out the panel using a flat-bladed tool. 4. Disconnect the instrument panel to console wiring harness connection. 5. Open the armrest in order to expose and remove the convenience tray from storage compartment. 6. Remove the fasteners (2) that retain the console (1) to the shifter assembly and the vehicle floor. 7. Remove the console from the vehicle by lifting the console over the floor studs. 8. If replacing the center console, remove the compact disc player from the console. Refer to Remote CD Player Replacement in Entertainment. 9. If replacing the center console, remove the amplifier from the console. Refer to Amplifier Replacement in Entertainment. 10. If replacing the center console, remove the rear seat audio control from the console. Refer to Audio Control Replacement - Rear Seat in Entertainment. 11. If replacing the center console, remove and retain the console wiring harness for use on the new console. Installation Procedure 1. Install the console wiring harness to the console. 2. Install the rear seat audio control to the console. 3. Install the amplifier from the console. 4. Install the compact disc player from the console. Important: Do not pinch the instrument panel to console wiring harness during this process. 5. Install the console to the vehicle by lifting the console (1) over and onto the floor studs. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the fasteners (2) that retain the console to the vehicle. Page 7953 7. Install the hood release cable grommet. 8. Install the hood latch cable to the latch. 9. Install the body hinge pillar trim panel. 10. Install the screws securing the underhood fuse block. 11. Install the windshield wiper/washer reservoir. 12. Connect the negative battery cable. 13. Inspect the hood latch release cable for proper operation. 14. Close the hood. Page 1474 5. Remove the camshaft sprocket bolts. 6. Remove the camshaft sprocket and the camshaft timing chain. 7. Remove the crankshaft sprocket using the J 5825-A. Page 5620 Application Table Part 5 Page 8205 Trim Panel Replacement - Body Side (Crew Cab) Removal Procedure 1. Remove the door sill trim plate. 2. Remove the upper seat belt anchor bolt (3) and the lower seat belt anchor bolt (7). Page 6662 8. Remove the heater outlet hose from the retaining clip at the engine water outlet. 9. Open the outlet heater hose retaining clip above the right side valve cover. Use a flat bladed tool to open the clip from the bottom. 10. Remove the outlet heater hose from the vehicle. INSTALLATION PROCEDURE 1. Apply lubricant, GM P/N 9985662, to each end of the outlet heater hose. 2. Install the outlet heater hose to the vehicle. IMPORTANT:When installing new outlet heater hose, place the clamp on the hose before installing the hose to the vehicle. Page 5496 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 6482 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 3596 Electronic Components Locations Endgate Harness Routing View Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 1579 10. Connect the breather tube to the air cleaner outlet duct. Page 494 Engine Generator And Starter Page 9746 Door Lock And Window Switch - Front Passenger C1 Part 1 Page 2715 Class 2 Serial Data Page 5680 C211 (Steering Column Harness To Body Harness) Part 5 Page 3021 Steps 1-3 Page 2030 Disclaimer Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 4883 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 9502 English Prevailing Torque Fastener Minimum Torque Development Part 1 Driver Information Center Module Replacement Driver/Vehicle Information Display: Service and Repair Driver Information Center Module Replacement DRIVER INFORMATION CENTER MODULE REPLACEMENT REMOVAL PROCEDURE 1. Using a flat-bladed tool, carefully remove the display lens (1) from the overhead console (3). 2. Remove the electronic display module (2) from the console (3). 3. Disconnect the electrical connection. INSTALLATION PROCEDURE 1. Connect the electrical connection. 2. Install the electronic display module (2) to the overhead console (3). 3. Install the display lens (1) by snapping the lens into place. 4. Calibrate the compass. Page 2726 Steps 1-3 Page 1407 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage Page 4257 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the electrical connector from the vehicle speed sensor. 3. Remove the following parts: ^ The vehicle speed sensor ^ The O-ring seal Installation Procedure 1. Coat a new O-ring seal with a thin film of transmission oil. Notice: Refer to Fastener Notice in Service Precautions. Door Window Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Window The outer door weatherstrip is used in order to seal the inner and outer door panels and the window at the belt line. The outer door weatherstrip can be replaced. Do not remove the inner sealing strip since the strip is stapled to the trim panel. Removal Procedure 1. Open the window. 2. Remove outer door weather strip from the door. Installation Procedure 1. Position the weatherstrip and press it into place. 2. Close the window. Page 5506 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 6265 Spare Tire: Service and Repair Spare Tire Carrier Replacement (2 Door 4WD Utility) Spare Tire Carrier Replacement (2 Door 4WD Utility) Removal Procedure 1. Remove the spare tire from the spare tire carrier mounting nuts. 2. Remove the spare tire from the spare tire carrier. 3. Open the spare tire carrier. 4. Remove the spare tire carrier mounting bolts and the washers. 5. Remove the spare tire carrier from the vehicle. Installation Procedure 1. Install the spare tire carrier to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Page 2981 Canister Purge Solenoid: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the evaporative emission (EVAP) purge pipe. 2. Disconnect the purge solenoid electrical connector. 3. Remove the purge solenoid mounting nuts. 4. Remove the engine wiring harness bracket from the mounting stud. Page 5030 Abbreviations And Meanings - Part 19 Page 4163 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: ^ General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle ^ Classify the failure of the wheel bearing with the aid of the illustrations. ^ Determine the cause of the wheel bearing failure. ^ Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Locations Ignition Coil, Ignition Control Module (ICM), Manifold Absolute Pressure (MAP) Sensor, Throttle Body, And EVAP Canister Purge Solenoid NV 1500 Transmission Mount: Service and Repair NV 1500 Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission mounting bolts. 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure Page 1545 ^ Worn, grooved, or damaged crankshaft front oil sealing surface (2) Minor imperfections on the crankshaft balancer crankshaft front oil seal surface may be removed with a polishing compound or fine grade emery cloth. ^ Worn, chunking, or deteriorated rubber (3) between the hub and the outer ring ^ Worn or damaged keyway (4) ^ Worn or damaged bolt hole threads (5) Installation Procedure 1. Apply a small amount of grease to the crankshaft front cover oil seal sealing surface if reusing the seal. Look to ensure that the front groove pin (crankshaft balancer) is installed in the proper location (if applicable). The length and location of the pins must be the same as the original length and location. Notice: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. 2. Apply a small amount of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent onto the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint. 3. Align the keyway of the crankshaft balancer with the crankshaft balancer key. 4. Install the crankshaft balancer onto the end of the crankshaft. Page 5597 Fuse Block - Underhood Connector C3 Part 2 Page 6490 Conversion English/Metric Part 1 Page 6677 5. Install the compressor hose assembly to the accumulator. Tighten Tighten the hose to...........................48 N.m (35 lb ft). 6. Install the sealing washers. 7. Install the compressor hose assembly to the compressor. 8. Install the compressor hose assembly washer (2) and the bolt (1). Tighten Tighten the bolt to..............................33 N.m (24 lb ft). 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400-A. Page 4636 5. Using J26267, install the front caliper piston boot.. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bleeder valve. Tighten the bleeder valve to 12 Nm (110 inch lbs.). Page 7139 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 203 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Page 7288 Abbreviations And Meanings - Part 14 Page 6683 7. Replace the seal washers. 8. Install the A/C compressor hose assembly to the A/C compressor. 9. Install the A/C compressor hose assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the bolt to..........................32 N.m (24 lb ft). 10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using J 42220. Wheel Speed Sensor (WSS) - LF Page 8384 WA820K/94 - WA8554/40 Service and Repair Tailgate Shock / Support: Service and Repair Strut Replacement - End Gate Removal Procedure 1. Open and support the endgate. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the endgate struts using a small flat-bladed tool. 3. Remove the upper end of the endgate struts from the ball joint. 4. Remove the lower end of the endgate struts from the ball joint. 5. Remove the endgate struts from the endgate. Installation Procedure 1. Position the endgate struts to the endgate. 2. Install the upper end of the endgate struts to the ball joint. Press in to place until fully seated. 3. Install the lower end of the endgate struts to the ball joint. Press in to place until fully seated. 4. Remove the support from the endgate. 5. Close the endgate. Page 8755 Seat Adjuster Switch - Driver/Front Passenger (w/ Memory) Part 1 Page 8392 WA8624/50 - WA882K/90 Page 9729 Abbreviations And Meanings - Part 19 Page 3795 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 7469 5. Close the center armrest. Page 3566 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Specifications Power Steering Pump: Specifications Power Steering Pump Front Mounting Bolts (4.3L) 37 ft. lbs. Power Steering Pump Front Mounting Nut (4.3L) 31 ft. lbs. Power Steering Pump Rear Mounting Bracket Nut (4.3L) 31 ft. lbs. Page 9776 Page 5856 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 3491 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 3864 3.2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. 6. Enable the SIR system. Page 8397 WA9539/47 - WA9539/47 Page 4158 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5673 C209 (Dome Harness To Body Harness) Part 2 Page 865 centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Page 4876 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Service and Repair Fluid Transfer Tube: Service and Repair Filler Tube and Seal Replacement Removal Procedure 1. If the vehicle is equipped with a 2.2L engine, remove the bolt securing the dipstick to the exhaust manifold. 2. Remove the transmission oil level indicator. 3. Raise the vehicle. 4. If the vehicle is equipped with a 2.2L engine, proceed to step 7. 5. If the vehicle is equipped with a 4.3L engine, remove the exhaust manifold pipe 6. Remove the rear propeller shaft. 7. Support the transmission and transfer case, if equipped, with a suitable jack. 8. Remove the transmission support. 9. Lower the transmission to gain access to the bolt securing the filler tube to the transmission torque converter housing. Page 8426 Luggage Rack: Specifications Fastener Tightening Specifications (ZRX/EXTREME w/ CF5) Fastener Tightening Specifications (ZRX/EXTREME w/ CF5) Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 8917 2. Remove all bends and twists from the cruise control module ribbon and cable, by rotating until removed. 3. Attach the cruise control cable bead (2) to the cruise control module ribbon (1). IMPORTANT: Do not twist the cruise control module ribbon (1). - Pull the cruise control cable (2) to verify retention to the ribbon (1). 1. Check the orientation of the cruise control ribbon buckle to the cable end fitting. Page 5481 Page 5608 Relay Block - Body Part 4 Page 6961 Disclaimer Page 1577 1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover. 2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover. 3. Install the valve rocker arm cover onto the cylinder head. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve rocker arm cover bolts. Tighten the valve rocker arm cover bolts to 12 Nm (106 inch lbs.). 5. Install the radiator inlet hose to the water outlet housing. 6. Fill the cooling system. Page 5770 C411 (Body Harness To Endgate Harness) Page 1222 Fuse Block - Underhood Connector C3 Part 1 Page 5077 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 4646 7. Remove the boot from the front brake caliper. Important: When removing the, front brake caliper piston seal, use a non metallic tool. 8. Remove the front brake caliper piston seal. 9. Remove the bleeder valve from the brake caliper body. 10. Clean the following items with denatured alcohol. ^ The bleeder valve ^ The brake caliper body bore ^ The brake caliper piston Important: If the corrosion cannot be removed, replace the brake caliper housing and piston. 11. Using a crocus cloth, clean the corrosion from the brake caliper bore. 12. Dry the parts using non lubricated, filtered compressed air. 13. Replace the brake caliper or the piston if any of the following conditions exist: Page 5858 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 8989 Abbreviations And Meanings - Part 1 Page 5584 Fuse Block - Underhood Connector C1 Part 1 Page 9335 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 7885 8. Install the sunroof panel window garnish molding (3). 9. Install the 15A fuse to the jumper harness as removed. Page 3565 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side NV 1500 Fluid - M/T: Service and Repair NV 1500 Transmission Fluid Replacement ^ Tools Required J36511 Oil Fill/Drain Plug Hex Bit (17 mm) Removal Procedure 1. Raise the vehicle. 2. Thoroughly clean around the fill plug and the oil drain plug. 3. Use the J 36511 in order to remove the oil fill plug. 4. Catch the oil in a suitable container. 5. Use the J 36511 in order to remove the oil drain plug. Installation Procedure OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 3174 Page 5001 Arrows And Symbols Uses various symbols in order to describe different service operations Page 8191 4. Remove the 2 short screws (1, 2) from the sunroof panel window garnish molding. 5. Remove the 8 screw covers (3) from the lower sunroof panel window garnish molding. 6. Remove the 8 garnish molding screws. 7. Remove the sunroof panel window garnish molding from the vehicle. Installation Procedure 1. Position the garnish molding to the headliner. 2. Ensure the sunroof switch wiring is positioned properly through the garnish molding. Page 4895 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4435 Disclaimer Page 311 Locations Vehicle Speed Sensor: Locations Manual Transmission, LH Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 323 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9005 Abbreviations And Meanings - Part 17 Page 9468 Page 4878 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 9607 Equivalent - Decimal And Metric Part 2 Page 3217 11. Disconnect the throttle position (TP) sensor harness connector. 12. Remove the throttle body retaining studs. 13. Remove the throttle body assembly. 14. Discard the throttle body seal. INSTALLATION PROCEDURE 1. Clean the seal surface on the intake manifold. CAUTION: Refer to Safety Glasses Caution in Service Precautions. Page 5305 C108 - Electric Shift Transfer Case Extension Harness To Body Harness, NP1 Page 9314 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 5359 C430 (Chassis Harness To License Lamp Harness) (Domestic) Page 7095 Equivalent - Decimal And Metric Part 2 Page 5234 C106 (Forward Lamp Harness To Body Harness) Part 1 Page 1761 40. Connect the breather tube to the air cleaner outlet duct. 41. Fill the cooling system. 42. Connect the battery negative cable. Page 9464 Electronic Components Electronic Components Page 5102 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4928 Registered And Non-Registered Trademarks - Part 1 Page 5319 C203 (Body Harness To IP Harness) Part 7 Page 9939 Windshield Washer Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Use a flat-bladed tool in order to pry the switch away from the instrument panel. 3. Disconnect the electrical connectors as necessary. INSTALLATION PROCEDURE 1. Connect the electrical connectors as necessary. 2. Install the switch to the instrument panel. 3. Connect the negative battery cable. Page 93 Memory Seat Module - Driver C1 Part 2 Page 8849 Truck Bed: Service and Repair Pickup Box Side Panel Replacement - Rear Step PICKUP BOX SIDE PANEL REPLACEMENT - REAR STEP REMOVAL PROCEDURE 1. Use a flat-bladed tool in order to pry the step upward. 2. Remove the step pad from the panel. 3. Remove the rear brace from the step panel. 4. Remove the splash shield from the wheelhouse. Page 5059 Page 3544 Disclaimer Page 2086 7. Remove the thermostat. 8. Clean all the sealing surfaces of the water outlet housing. 9. Clean the sealing surface on the lower intake manifold. Installation Procedure Important: In order to prevent leakage, thoroughly clean all parts and sealing surfaces. 1. Install the thermostat. 2. Install a new gasket or O-ring. 3. Install the water outlet housing to the lower intake manifold. Notice: Refer to Fastener Notice in Service Precautions. Page 5269 C223 (IP Harness To Auxiliary Power Tray) (Extended Cab) Page 6872 Seat Belt: Service and Repair Seat Belt Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear seat assembly. 2. Remove the lower seat belt anchor plate from the rear seat bolt. 3. Remove the upper seat belt anchor bolt cover. 4. Remove the bolt that retains the upper seat belt anchor plate. 5. Remove the body side trim panel. 6. Guide the seat belt through the opening in the body side trim panel. Page 2355 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Remove the front hood bumper by turning the front hood bumper (1) out counterclockwise. 2. Remove the side hood bumper by sliding the side hood bumper (2) rearward and pulling up. Installation Procedure 1. Install the side hood bumper by pushing down and sliding the side hood bumper (2) forward. 2. Install the front hood bumper (1) by turning the front hood bumper in clockwise until the hood closes flush with the fender. Page 8457 2. Keeping the position lock pin on the new SOP switch, align the switch over the drive cables. IMPORTANT: The SOP switch comes from the factory with a position lock pin that is installed on top of the switch. This locks the timing gears in place. Do not remove the position lock pin until after the SOP switch and the actuator are installed. 3. Apply pressure to the SOP switch until the switch is completely seated. If the switch does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOP switch. Lift each cable into the switch, and press down on the assembly until the assembly is completely seated. 4. Install the screw which secures the SOP switch to the sunroof module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 3.4 N.m (30 lb in). 5. Connect the electrical connector to the SOP switch. 6. Install the sunroof motor/actuator. 7. Remove the position lock pin (1). 8. Remove the 2 alignment pins from the cable mechanisms and/or from the cam mechanisms. 9. Install the sunroof control module, but do not install the headliner until after the sunroof operation has been verified. 10. Verify the operation of the sunroof module. 11. Install the sunroof window. 12. Install the headliner. Page 6073 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 7066 Page 5765 C317 (Body Harness To Driver's Seat Assembly Pigtail Connector) Page 362 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Locations Body Harness to Cowl Page 9640 Abbreviations And Meanings - Part 21 Page 9632 Abbreviations And Meanings - Part 13 Page 7122 Abbreviations And Meanings - Part 15 Page 9550 Steps 1-5 Page 5223 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 9604 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 1091 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 7080 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 2731 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 6747 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner outlet duct. 3. Disconnect the A/C high pressure switch electrical connector (2). 4. Remove the A/C high pressure switch connector retaining ring. 5. Remove the A/C high pressure switch from the A/C compressor. INSTALLATION PROCEDURE 1. Install the A/C high pressure switch to the A/C compressor. 2. Install the A/C high pressure switch connector retaining ring. 3. Connect the A/C high pressure switch electrical connector (2). 4. Install the air cleaner outlet duct. 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings of the components using the J 39400-A. Page 8516 6. Cut the tie straps securing the sunroof power feed wire to the body harness. IMPORTANT: Note the routing of the sunroof main feed wire on the body harness routed down the windshield pillar. 7. Cut the gray connector off the old main feed wire. 8. Tie the old wire onto the new main feed wire in order to aid in the location of the new wire. 9. Pull rearward, the LF center section of the door weather seal (1). 10. Located underneath the instrument panel, pull the new wire (2) up through and next to the left side of the instrument panel end cap (3). INSTALLATION PROCEDURE 1. Secure the sunroof wire to the windshield pillar body harness with new tie straps. 2. Position the new wire across the left front upper headliner area. 3. Connect the gray connector end of the wire (2) to the fused jumper at the lower fuse block. 4. Connect the electrical connector (1) to the sunroof switch connector. 5. Install the LF windshield pillar garnish molding. 6. Install the LF sunshade and retainer. 7. Reposition the LF door seal on the pinchweld flange. Page 5149 Location View Page 7379 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 8139 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 2669 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 6932 1. Install the antenna mast to the antenna base. 2. Screw the antenna mast to the antenna base. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the antenna mast to 5 N.m (44 lb in). Page 2921 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 9471 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6219 When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations Page 7243 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 5960 2. Install the power steering cooler retaining bolts. Tighten the power steering cooler retaining bolts to 10 Nm (7 ft. lbs.). 3. Reposition the hood latch support to the radiator core support. 4. Install the hood latch support mounting bolts. Tighten the hood latch support mounting bolts to 25 Nm (18 ft. lbs.). 5. Reposition the radiator air intake baffle to the radiator core support. 6. Install the radiator air intake baffle retaining clips to the LH side. 7. Install the grille. Specifications Timing Cover: Specifications Engine Front Cover Bolt ...................................................................................................................... ............................................... 12 Nm (106 inch lbs.) Page 502 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 5488 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Locations Left Hand Side Of Instrument Panel Page 9523 Abbreviations And Meanings - Part 19 Page 3186 Steps 10-11 Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Page 5653 C109 (Body Harness To The 4WAL/SIR Harness) Page 3101 Step 6 Page 2239 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 4764 5. Install the pushrod retainer to the brake pedal pin. The retainer will snap into place. 6. Install the left closeout/insulator panel. 7. Install the check valve to the vacuum booster. 8. Install the master cylinder. Page 8846 6. Remove the retainers that secure the step panel to the outer panel. 7. Remove the step panel from the side outer panel. 8. Remove the nuts that secure the forward and rear support brackets to the pickup box cross sills. INSTALLATION PROCEDURE 1. Loosely install the front and rear support brackets onto the number 1 and number 2 cross sill studs using 2 nuts for each. Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure 1. Open and support the hood. 2. Disconnect the negative battery cable. 3. Remove the windshield wiper washer reservoir. 4. Remove the screws securing the underhood fuse block in order to pull the unit away from the fender. Important: Block the hood latch in order to prevent the hood from locking until you have installed the hood latch release cable. 5. Disconnect the hood latch cable from the primary latch assembly. Use a flat-bladed tool in order to release the clip and lift the cable assembly from the primary latch. 6. In order to aid in installation, tie a mechanic's wire to the end of the cable. 7. Remove the clips that retain the hood release cable. Pry open the clips with a flat-bladed tool. 8. Pull the cable back through the opening between the radiator support and the left fender. 9. Pull the cable back from behind the antilock brake module. 10. Remove the body hinge trim panel. 11. Remove the hood release cable grommet. 12. Remove the adhesive tape securing the release cable to the side of the cowl. 13. Remove the hood release cable and the lever bolts from the cowl side panel. 14. Remove the hood latch cable assembly from the vehicle. Page 5609 Relay Block - Body Part 5 Page 9853 Window Switch - RR Page 1900 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 124 Tighten Tighten the cruise control module nuts to 9.0 N.m (6.6 lb ft). 4. Connect the electrical connector. 5. Install the cruise control cable. 6. Connect the battery negative cable. 7. Test the systems operation. Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Rear Door (Utility) Trim Panel Replacement - Side Rear Door (Utility) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the window weatherstrip. 2. Remove the door handle bezel. 3. Remove the window regulator handle, if equipped. 4. Remove the power window switch, if equipped. 5. Remove the trim panel screws from the armrest. Carefully pry off the cover using a flat-bladed tool. 6. Use the J 38778 in order to release the door trim panel retainers. 7. Remove the door trim panel from the door. Installation Procedure 1. Install the door trim panel to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the trim panel armrest screws to the armrest. Tighten the screws to 1.9 N.m (17 lb in). 3. Position the cover and snap the cover into place. 4. Install the power window switch, if equipped. 5. Install the window regulator handle, if equipped. 6. Install the inside door handle bezel. 7. Install the window weatherstrip. Rear Side Door Trim Panel Replacement TRIM PANEL REPLACEMENT - SIDE REAR DOOR (UTILITY) TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover Page 2333 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Spare Tire Carrier Replacement (2 Door RWD Utility) Spare Tire: Service and Repair Spare Tire Carrier Replacement (2 Door RWD Utility) Spare Tire Carrier Replacement (2 Door RWD Utility) Removal Procedure 1. Remove the spare tire cover. 2. Remove the spare tire from the spare tire carrier mounting nut. 3. Remove the spare tire from the spare tire carrier. 4. Remove the spare tire carrier to body side inner panel mounting bolts. 5. Remove the spare tire carrier from the vehicle. Installation Procedure 1. Install the spare tire carrier to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Page 6220 The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears Page 5289 C411 (Body Harness To Endgate Harness) Page 8545 Power Seat Motor: Diagrams Seat Front Vertical Motor - Driver Page 2659 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 6588 5. Thread the J 33013-B into the hub. 6. Remove the hub and drive plate assembly (1) by turning the center screw into the body of the J 33013-B and against the A/C compressor shaft. 7. Remove the shaft key and retain for reassembly. With RPO Code HT6/HD6/HU6 COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED - J 34992 Compressor Holding Fixture - J 33013-B Hub and Drive Plate Remover/Installer 1. Clamp the J 34992 in a vise. 2. Use thumb screws in order to attach the compressor to the holding fixture. 3. Ensure that the center screw forces the tip to thrust against the end of the shaft. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 4. Thread the J 33013-B into the hub. 5. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). 6. Remove the shaft key. Retain the shaft key for reassembly. Page 4541 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 1665 2. Install the oil level indicator tube into the engine block. Rotate the oil level indicator tube into position. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil level indicator tube bolt. Tighten the oil level indicator tube bolt to 12 Nm (106 inch lbs.). 4. Install the right exhaust manifold. 5. Install the oil level indicator. Page 4762 Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure 1. Apply the parking brake. 2. Remove the master cylinder away from the vacuum booster. 3. Support the master cylinder. 4. Disconnect the check valve from the vacuum booster. 5. Remove the left closeout/insulator panel. 6. Remove the pushrod retainer from the brake pedal pin. 7. Remove the stop lamp switch and the pushrod from the brake pedal pin. 8. Remove the steering column support bracket. Page 3738 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 7686 Abbreviations And Meanings - Part 14 Page 2257 Intake Air Temperature (IAT) Sensor 1. Install the IAT sensor by gently pushing the sensor into the air cleaner outlet duct until seated. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Page 5781 C501 (Body Harness To LF Door Harness) (2-Door Export) Part 1 Page 9580 Page 5687 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 1 Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 2922 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 1060 7. Replace the seal washers. 8. Install the A/C compressor hose assembly to the A/C compressor. 9. Install the A/C compressor hose assembly bolt. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the bolt to..........................32 N.m (24 lb ft). 10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using J 42220. Page 6088 Abbreviations And Meanings - Part 11 Page 9808 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 3590 Shift Interlock Solenoid: Diagrams W/Floor Shift W/ Column Shift Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 3116 1. Apply a few drops of clean engine oil to the male fuel pipe end. CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure. Page 5925 5. Disconnect the relay rod ball stud from the pitman arm using J 24319-B. 6. Remove the relay rod ball stud nut at the idler arm. 7. Disconnect the relay rod from the idler arm using J 24319-B. 8. Remove the relay rod. 9. Inspect the following components: ^ The threads on the tie rod for damage ^ The threads on the tie rod end for damage ^ The ball stud threads for damage ^ The ball stud seals for excessive wear 10. Clean the threads on the ball stud and ball stud nut. Installation Procedure 1. Install the relay rod ball stud to the idler arm. Ensure that the seal is on the stud. Page 7067 Page 1601 Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seal. The exhaust valve oil stem seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal, or the material may be red in color (2) with no paint stripe. The intake valve oil seal is black in color. 1. Assemble the valve into the proper valve guide. 2. Select the proper valve stem oil seal for the specific valve guide. 3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil. 4. Assemble the valve stem oil seal onto the valve stem. Caution: Refer to Safety Glasses Caution in Service Precautions. 5. Using the J 42073, install the valve stem oil seal onto the valve guide. 5.1. Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat. 5.2. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. There should be a 1 - 2 mm (0.03937 - 0.07874 inch) gap between the bottom edge of the valve stem oil seal and the valve guide. 6. Install the valve spring (3). 7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Page 825 Door Lock And Window Switch - Driver C1 Part 2 Page 5596 Fuse Block - Underhood Connector C3 Part 1 Page 5699 Multiple Junction Connector: Diagrams C401 - C433 C402 (Body Harness To RH Tail Lamp Harness) (Domestic) Page 1336 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 967 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Page 2896 Engine, LR Page 8568 Seat Adjuster Switch - Driver C1 (w/ 8-Way, w/o Memory) Part 1 Page 788 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 8348 WA8555/41 - WA8555/41 Page 6126 Tighten the outer tie rod ball stud nut to the steering knuckle to 53 Nm (39 ft. lbs.). Important: Do not back the nut off in order to align the cotter pin hole. Advance the nut in order to align the nut slot with the cotter pin hole. 10. Install the new cotter pin to the outer tie rod stud nut. 11. Spread the cotter pin ends. 12. Lower the vehicle. 13. Adjust the front toe. 14. Position the two clamps (2) between the locating dimples (1) at either end of the adjuster tube. 15. The clamps must be positioned within the correct angular travel, as shown. 16. Ensure that the clamp slot (2) is not aligned with the adjuster tube slot (1). 17. Maintain the position of each tie rod end as the clamps are tightened in order to ensure free movement of each joint. 18. When clamps are tightened to specifications, the ends may touch. 19. Install the adjuster tube clamp bolts. Tighten the adjuster tube clamp bolts to 21 Nm (16 ft. lbs.). Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6466 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module (BCM) C1 Part 1 Specifications Fuel Gauge Sender: Specifications Page 9115 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 8025 clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as 50 mm up from the front door ditch and 75 mm back from the front door front edge. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/name plate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/name plate. 7. Position the emblem/name plate to the location marks and press the emblem/name plate to the mounting surface. 8. Apply equal pressure along the emblem/name plate in order to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Page 3853 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 798 Abbreviations And Meanings - Part 7 Page 7101 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 6653 Heater Core: Service and Repair Heater Core Replacement Removal Procedure 1. Remove the heater/vent module. See: Housing Assembly HVAC/Service and Repair 2. Remove the heater core access cover screws. 3. Remove the heater core access cover. 4. Remove the heater core from the heater/vent module. Installation Procedure Testing and Inspection Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids Inspect the connectors at the BCM, and all other circuit connecting points for an intermittent condition. Inspect the circuit wiring for an intermittent condition. If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Page 5297 C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 2 C101 (Body Harness To Engine Harness) Part 1 Page 7691 Abbreviations And Meanings - Part 19 Locations Electronic Components Page 197 Ignition Control Module: Description and Operation IGNITION COIL AND ICM The ICM is connected to the PCM by an ignition control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Page 5292 C430 (Chassis Harness To License Lamp Harness) (Domestic) Page 5210 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 6428 1. Install the air temperature actuator to the HVAC module. Ensure that the actuator is seated on the locating tab. 2. Install the air temperature actuator retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 3. Connect the electrical connector (2). 4. Install the instrument panel carrier. Page 4624 ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the piston is fully seated in the brake caliper bore. ^ Remove the C-clamp from the caliper. 7. Remove the brake caliper hose bolt from the brake caliper. 8. Remove the 2 metal gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 9. Discard the 2 metal gaskets. 10. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 11. Remove the brake caliper mounting bolts. 12. Remove the brake caliper. 13. Remove the brake pads from the brake caliper. 14. Remove the brake caliper mounting bolt sleeves. 15. Remove the rubber O-rings. Page 8681 Abbreviations And Meanings - Part 1 Page 9710 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 7150 Driver/Vehicle Information Display: Service and Repair Driver Information Center Replacement (With Sunroof) DRIVER INFORMATION CENTER REPLACEMENT (WITH SUNROOF) REMOVAL PROCEDURE 1. Remove the screw at the front of the console that retains the sunroof console to the roof. 2. Pull downward on the rear of the console in order to remove the sunroof console from the roof. 3. Disconnect the electrical connectors (1, 5, 6) as needed. 4. Remove the screw that retains the sunroof console mounting bracket to the roof. INSTALLATION PROCEDURE 1. Install the electrical connectors (1, 5, 6) as needed. 2. Insert the console mounting tabs into the mounting bracket and push upward on the rear of the console in order to install the console. 3. Install the screw at the front of the console that retains the console to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 1.9 N.m (17 lb in). Page 4953 Disclaimer Page 7734 Body Control Module (BCM) C3 Part 2 Page 4249 1. Install the transmission mount to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to the transmission mounting bolts. ^ For vehicles equipped with 2.2L, tighten the bolts to 45 Nm (33 ft. lbs.). For vehicles equipped with 4.3L, tighten the bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut. ^ Tighten the nut to 57 Nm (42 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Page 2334 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Page 7810 Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door Tools Required J 38778 Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the inside door handle bezel. 2. Remove the window regulator handle, if equipped. 3. Remove the power accessory switch mounting panel, if equipped with power accessories. 4. Remove the trim panel armrest screws. 5. Use the J 38778 in order to release the door trim panel retainers. 6. Remove the door trim panel from the door. Installation Procedure 1. Install the door trim panel to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the trim panel armrest screws. Tighten the screws to 1.9 N.m (17 lb in). 3. Install the power accessory switch mounting plate, if equipped with power accessories. 4. Install the window regulator handle, if equipped. 5. Install the inside door handle bezel. A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 5006 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9699 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Service and Repair Windshield Washer Hose: Service and Repair HOSE REPLACEMENT - WINDSHIELD WASHER REMOVAL PROCEDURE 1. Raise and support the hood. 2. Remove the hose from the nozzles. 3. Remove the hose clip from the hood. 4. Disconnect the hose from the pump. 5. Remove the hose. INSTALLATION PROCEDURE Page 4269 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Wheel Speed Sensor (WSS) - LF Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Light Switch Mounting Bolt 35 inch lbs. Page 1365 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Service and Repair Power Steering Bleeding: Service and Repair Bleeding the Power Steering System ^ Tools Required J 35555 Metal Mityvac - J 43485 Power Steering Bleeder Adapter Important: Hoses touching the frame, body, or engine may cause system noise. 1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system. 2. Verify that all hose connections are tight. Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Important: Maintain the fluid level throughout the bleed procedure. 3. Remove the pump reservoir cap. Important: Use clean, new power steering fluid only. 4. Fill the pump reservoir with fluid to the FULL COLD level. 5. Attach the J 43485 to the J 35555 or equivalent. 6. Place the J 43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 inch-Hg) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7 - 10 kPa (2 - 3 inch-Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis at the end of this procedure. 9. Remove the J 43485 and the J 35555. 10. Reinstall the pump reservoir cap. 11. Start the engine. Allow the engine to idle. Page 8766 2. Connect the electrical connector to the switch. 3. Install the trim panel to the seat with the 3 screws. 4. Install the seat to the vehicle. Locations Electronic Components Page 8704 Abbreviations And Meanings - Part 24 Specifications Piston Ring: Specifications Piston Rings Piston Ring End Gap - First Compression Ring - Production ................................................................................... 0.25 - 0.40 mm (0.010 - 0.016 inch) Piston Ring End Gap - Second Compression Ring - Production ............................................................................... 0.38 - 0 58 mm (0.015 - 0.023 inch) Piston Ring End Gap - Oil Control Ring - Production .............................................................................................. 0.25 - 0.76 mm (0.010 - 0.029 inch) Piston Ring End Gap - First Compression Ring - Service ......................................................................................... 0.25 - 0.50 mm (0.010 - 0.020 inch) Piston Ring End Gap - Second Compression Ring - Service .................................................................................... 0.38 - 0.80 mm (0.015 - 0.031 inch) Piston Ring End Gap - Oil Control Ring - Service ............................................................................................ 0.005 - 0.090 mm (0.0002 - 0.0035 inch) Piston Ring to Groove Clearance - First Compression Ring - Production ........................................................ 0.030 - 0.070 mm (0.0012 - 0.0027 inch) Piston Ring to Groove Clearance - Second Compression Ring - Production .................................................... 0.076 - 0.280 mm (0.0030 - 0.0110 inch) Piston Ring to Groove Clearance - Oil Control Ring - Production ................................................................... 0.046 - 0.196 mm (0.0018 - 0.0077 inch) Piston Ring to Groove Clearance - First Compression Ring - Service .............................................................. 0.030 - 0.085 mm (0.0012 - 0.0033 inch) Piston Ring to Groove Clearance - Second Compression Ring - Service .......................................................... 0.030 - 0.085 mm (0.0012 - 0.0033 inch) Piston Ring to Groove Clearance - Oil Control Ring - Service ......................................................................... 0.076 - 0.200 mm (0.0030 - 0.0079 inch) Page 9017 Registered And Non-Registered Trademarks - Part 2 Electronic Components Electronic Components Page 7246 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 6753 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (5) from the accumulator. INSTALLATION PROCEDURE 1. Install the A/C low pressure switch (5) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the A/C low pressure switch to................5 N.m (44 lb in). 2. Connect the A/C low pressure switch electrical connector. 3. Leak test the fittings of the component using the J 39400-A. Page 4466 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 4270 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 3576 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 975 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Step 1 - 12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked may will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the Page 9097 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8391 WA8624/50 - WA8624/50 Page 8273 Power Door Lock Switch: Service and Repair POWER ACCESSORY SWITCH PANEL REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the power accessory switch panel from the armrest. Use a flat-bladed tool in order to carefully pry the cover up at the front leading edge. 3. Disconnect the electrical connectors from the switch. 4. Remove the switches from the switch mounting panel, if necessary. INSTALLATION PROCEDURE 1. Install the switches to the switch mounting panel, if necessary. 2. Connect the electrical connectors to the switch. 3. Install the power accessory switch mounting panel to the armrest. Ensure that the retainers lock into place. 4. Connect the battery negative cable. Page 3163 INSTALLATION PROCEDURE 1. Install the fuel fill and vent pipes and hoses to the fuel tank and the fill pipe housing. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the vent hose clamp (1) to 1.7 N.m (15 lb in). - Tighten the fuel fill hose clamp (2) to 2.5 N.m (22 lb in). 1. Connect the fill pipe ground strap to the frame with the bolt (4) and washer (3). Tighten Tighten the ground strap bolt to 15 N.m (11 lb ft). 2. Lower the vehicle. Page 86 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 4853 Locations Relay Block - Body Relays, Except Envoy Page 556 Throttle Position (TP) Sensor Page 2901 4. Install the distributor. 5. Connect the negative battery cable. Page 827 Door Lock And Window Switch - Front Passenger C1 Part 1 Page 4122 1. Install the NEW clutch pilot bearing using the J 26516-A with the J 8092. 2. Measure to ensure the proper installation depth is obtained. 3. Install the flywheel. Page 5184 Fuse Block - Underhood Connector C3 Part 3 Page 4993 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 4353 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Page 1121 4. Apply sealant to the oil fill plug threads. Use Teflon GM P/N 1052080 or the equivalent. 5. Use the J 36511 in order to install the oil fill plug. ^ Tighten the oil fill plug to 30 Nm (22 ft. lbs.). 6. Remove the safety stands. 7. Lower the vehicle. Page 5764 C315 (Body Harness To Passenger Seat Assembly Pigtail Connector) 4-Door with Power Seats) Page 4305 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the electrical connector from the vehicle speed sensor. 3. Remove the following parts: ^ The vehicle speed sensor ^ The O-ring seal Installation Procedure 1. Coat a new O-ring seal with a thin film of transmission oil. Notice: Refer to Fastener Notice in Service Precautions. Page 9100 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 2375 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 4851 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5101 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 2698 Abbreviations And Meanings - Part 18 Page 7160 Disclaimer Page 9465 Page 998 Disclaimer Page 4530 3. Install the anti/rattle spring on the rear brake caliper. 4. Install the brake caliper assembly on the mounting bracket. 5. Lower the vehicle. Refer to Vehicle Lifting. 6. Fill the brake master cylinder to the proper level. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 5-6 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Burnish the new brake pads. Page 2681 Abbreviations And Meanings - Part 1 Page 1228 Fuse Block - Underhood Connector C4 Part 4 Page 5163 Location View Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Connector Views Fuse Block: Connector Views Fuse Block - I/P Part 1 Page 9790 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 3136 Steps 4-7 Page 5623 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 1914 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at top dead center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1) or V8 engine (2). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when the gear is installed in the distributor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. Page 9828 Abbreviations And Meanings - Part 14 Page 7136 Registered And Non-Registered Trademarks - Part 2 Page 9717 Abbreviations And Meanings - Part 7 Page 6491 Conversion English/Metric Part 2 Page 8660 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 2427 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 8444 6. Let the drive tube motor block (3) hang on the assembly screw (1). 7. Remove the motor from the drive tube motor block. INSTALLATION PROCEDURE 1. Carefully lift open the sunroof window, with the palm of the hand. 2. Place hands at the front edge of the sunroof window. 3. Push rearward on both sides of the sunroof to the full open position. 4. Verify the leading edge of the sunroof window is parallel with the rear edge of the sunroof mainframe. 5. Install the sunroof motor/actuator to the drive tube motor block (3). 6. Position the motor/actuator to the drive tube motor block. 7. Apply Loctite® Blue, GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the motor/actuator screw threads. 8. Install the screws that retain the sunroof motor/actuator to the sunroof drive tube motor block (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 4.0 N.m (35 lb in). 9. Connect the electrical connector to the motor/actuator. 10. Ensure the electrical harness is tucked behind the motor/actuator prior to installing the garnish trim cover screw. 11. Install the motor/actuator garnish trim cover (1) to the window panel garnish molding (3). 12. Install the cover screw (2). Tighten Tighten the screw to 1.5 N.m (13 lb in). 13. Install the motor/actuator service cover. 14. Test the function of the sunroof through several cycles. Page 9822 Abbreviations And Meanings - Part 8 Page 5033 Abbreviations And Meanings - Part 22 Page 7462 6. Install the negative battery cable. Page 6506 Abbreviations And Meanings - Part 7 Page 5256 C204 (Column Shifter Plug To Body Harness) Page 9402 Abbreviations And Meanings - Part 15 Page 5926 Notice: Refer to Fastener Notice in Service Precautions. 2. Seat the taper using J 29193 or J 29194. Tighten J 29193 or J 29194 to 54 Nm (40 ft. lbs.) 3. Remove J 29193 or J 29194 from relay rod ball stud. 4. Install the new nut to the relay rod ball stud at the idler arm. Tighten the relay rod ball stud nut at the idler arm to 47 Nm (35 1b inch). 5. Install the relay rod ball stud to the pitman arm. Ensure that the seal is on the stud. 6. Seat the taper using J 29193 or J 29194. Tighten J 29193 or J 29194 to 54 Nm (40 ft. lbs.). 7. Remove J 29193 or J 29194 from relay rod ball stud. Page 4076 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 8689 Abbreviations And Meanings - Part 9 Page 5490 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8977 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 2884 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Disconnect the fuel tank pressure sensor electrical connector. 6. Remove the fuel tank pressure sensor (1) from fuel sender assembly (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) on the fuel sender assembly (2). 2. Connect the fuel tank pressure sensor electrical connector. 3. Install the fuel tank. 4. Refill the fuel tank. 5. Install the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 6732 Body Wiring To Blower Motor And Resistor (With RPO Code RPO C60) Page 8916 4. Disconnect the cruise control cable from the round hole in the engine cable bracket. 5. Disconnect the cruise control cable locator clip from the rectangular hole in the routing bracket. 6. Remove the cruise control cable from the cruise control module housing. 7. Disconnect the cruise control cable bead (2) from the end of the ribbon (1). IMPORTANT: Do not allow the cruise control ribbon (1) to retract into the module assembly. 8. Remove the cruise control cable from the vehicle. INSTALLATION PROCEDURE 1. Install the cruise control cable to the vehicle. Page 329 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 857 Page 5312 C201 (Steering Column Harness To Redundant Steering Wheel Control Harness) C203 - Body Harness to IP Harness Page 196 Ignition Control Module (ICM) Page 3234 Engine Harness Rear (4.3L) Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 6698 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .................................................................... R-134a Page 8188 Trim Panel: Service and Repair Garnish Molding Replacement - Rear Upper Garnish Molding Replacement - Rear Upper Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the rear header garnish molding. Insert the J 38778 and work along the front edge of the trim panel from one end to the other. 2. Remove the cargo lamp from the roof rear header garnish molding. Installation Procedure 1. Install the cargo lamp from the roof to the rear header garnish molding. 2. install the roof rear header garnish molding to the vehicle. Page 2680 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 4889 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1912 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the number 1 mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove the distributor and reinstall the distributor. 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the distributor clamp bolt to 25 N.m (18 lb ft). Page 5047 1. Install the starter and the inboard starter mounting bolt. Do not tighten. 2. Install the starter shims, if equipped. 3. Install the outboard starter mounting bolt. Tighten Tighten the starter mounting bolts to 50 N.m (37 lb ft). 4. Install the differential carrier shield, if equipped. 5. Install the differential carrier shield mounting bolts, if equipped. Page 7312 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener SYMPTOMS - GARAGE DOOR OPENER IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Page 5737 C204 (Column Shifter Plug To Body Harness) Page 2399 Step 8 Page 8572 Seat Adjuster Switch - Front Passenger C2 (w/ 8-Way, w/o Memory) Page 4649 3. Remove the pistons (2) from the caliper bores. 4. Remove the boots (1) from the caliper bores. Do not scratch the caliper bores. 5. Remove the piston seals (3) from the caliper bores. Do not use a metal tool. 6. Remove the bleeder valve cap (4). 7. Remove the bleeder valve (5) from the caliper housing (6). 8. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Replace the pistons or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore Use a crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Assembly Procedure 1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid. 2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves. 3. Install the boot seals (1) on the pistons (2). 4. Install the pistons in the caliper bores. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the bleeder valve (5) in the caliper housing (6). Tighten the bleeder valve to 7 Nm (62 inch lbs.). 6. Install the bleeder valve cap (4). Page 4903 Abbreviations And Meanings - Part 3 Page 5936 Idler Arm: Service and Repair Idler Arm Replacement ^ Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the idler arm mounting bolts and nuts from the frame. Important: Use the proper tool in order to separate all ball joints. 3. Remove the relay rod stud nut. 4. Disconnect the relay rod from the idler arm using J 24319-B. 5. Remove the idler arm. 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seal for cuts or other damage. 8. Clean the threads on the ball stud. 9. Clean the threads on the ball stud nut. Installation Procedure Page 2490 Intake Air Temperature Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. Intake Air Temperature (IAT) Sensor 3. Remove the IAT sensor by pulling straight out using a rotating motion. INSTALLATION PROCEDURE Page 8141 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 4338 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 1489 14. Inspect the valve lifter for the following: ^ Broken or damaged clip (1) ^ Worn pushrod socket (2) ^ Scuffed or worn lifter body (3) If the valve lifter shows scuffing or wear, inspect the engine block valve lifter bores for wear. ^ Worn roller (4) ^ Loose or damaged pin (5) ^ Plugged oil hole (6) Installation Procedure Important: It is normal for NEW lifters to make a slight ticking noise when the engine is first started. Increasing the engine RPMs slightly to raise oil pressure should stop the noise. 1. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent to the valve lifter rollers. Important: If reusing the valve lifters, install the valve lifters in the original positions. 2. Install the valve lifters. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve lifter pushrod guides. Tighten the valve lifter pushrod guide bolts to 16 Nm (12 ft. lbs.). Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure REMOVAL PROCEDURE 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Remove the battery ground negative cable and bolt from the battery 4.3L. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. INSTALLATION PROCEDURE Install the battery ground negative cable and bolt to the battery. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end. Tighten Tighten the battery terminal bolt to 15 N.m (11 lb ft). A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Locations Seat Switches Page 8061 3. Raise the frame slightly on the hoist. 4. Install the lower cushion. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the frame cushion bolts. Tighten the bolts to 70 N.m (52 lb ft). 6. Lower the hoist. Page 1352 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 3845 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 6501 Abbreviations And Meanings - Part 2 Page 7106 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 4368 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 4607 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure 1. Remove the brake shoes. 2. Disconnect the brake pipe. 3. Remove two bolts. 4. Remove the wheel cylinder. Installation Procedure 1. Install the wheel cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten the bolts to 13 Nm (115 inch lbs.). 3. Connect the brake pipe to the wheel cylinder. Tighten the brake pipe fitting to 21 Nm (16 ft. lbs.). 4. Install the brake shoes. 5. Bleed the brake system. Page 7678 Abbreviations And Meanings - Part 6 Page 7587 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1500 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Mark, sort, and organize all the components for assembly. 2. Remove the valve rocker arms. 3. Remove the valve rocker arm supports. 4. Remove the valve pushrods. Important: Parts that are to be reused must be marked, sorted, and organized for assembly. 5. Mark, sort, and organize the components for assembly. Diagrams Window Lockout Switch Page 4640 Important: When performing the following service procedure, DO NOT reuse the washers, replace them with new washers. 8. Install the front brake hose fitting, the 2 new gaskets and the brake hose fitting bolt. Tighten the front brake hose bolt to 54 Nm(40 ft. lbs.). 9. Fill the brake master cylinder to the proper level. 10. Bleed the brake caliper. 11. Inspect the brake system for leaks. 12. Install the tire and wheel assembly. 13. Lower the vehicle. Refer to Vehicle Lifting. Brake Caliper Replacement - Front (Dual Piston) Brake Caliper Replacement - Front (Dual Piston) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper hose bolt from the brake caliper. 4. Remove the 2 copper gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 5. Discard the 2 copper gaskets. 6. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 7. Remove the brake hose and washers from the brake caliper. Page 2521 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 2865 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 5157 Application Table Part 4 Page 6782 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Sunroof - Water Leaks Into The Interior Sunroof / Moonroof Drain: Customer Interest Sunroof - Water Leaks Into The Interior Bulletin No.: 03-08-57-005 Date: November 19, 2003 TECHNICAL Subject: Water Found In Rear Cupholder or On Floor of Vehicle (Reroute Rear Sunroof Drain Hose) Models: 2003-2004 Chevrolet Blazer (2-Door) 2003-2004 GMC Jimmy (2-Door) (Canada only) Built Prior to VIN Breakpoint 4K124402 Condition Some customers may comment on water in the rear trim panel cupholder or on the rear floor. Cause Important: Do not remove the energy absorbent foam from the headliner. It is a government requirement. Due to energy absorbent foam in the headliner, the hose runs upward and the water cannot drain. Correction Reroute the left and right rear sunroof drain hoses. 1. Fold the rear seats down. 2. Remove the front and rear upper seat belt anchor bolt. 3. Remove the assist handles. 4. Remove the coat hooks. 5. Remove the end gate sill plate. 6. Remove the rear upper garnish molding and unplug the connector for the cargo lamp. 7. Remove the spare tire and holder if the tire is inside the vehicle. 8. Remove the jack storage cover and the jack. 9. Remove the screw that retains the upper trim (left side only). Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement Removal Procedure 1. Carefully insert a flat-bladed tool between the cover and the handle in order to remove the assist handle covers. 2. Remove the screws that retain the assist handle to the vehicle. 3. Remove the assist handle from the vehicle. Installation Procedure 1. Install the assist handle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the assist handle to the vehicle. Tighten the screws to 9 N.m (80 lb in). 3. Install the assist handle covers. Position the covers and snap into place. Page 8440 Sunroof Motor (Sunroof Switch C1) Page 8398 WA9539/47 - WA9792/39 Page 9407 Abbreviations And Meanings - Part 20 Page 8466 6. Install the long gold assembly screw (1). 7. Install the sunroof window. 8. Install the motor/actuator. Page 8625 4. Remove the trim plate. 5. Separate the J-strips from the seat bottom frame. Important: Do not damage the seat fabric when removing the velcro retaining cover. 6. Separate the hook and loop strips (1) that retain the seat pad (3) to the seat cover (2). 7. Disconnect the electrical connections, as needed. 8. Remove the seat back release lever, if equipped. 9. Remove the manual lumbar support knob, if equipped. 10. Remove the power seat control switch, if equipped. 11. Remove the seat back from the seat bottom bolts. 12. Remove the seat belt buckle bolt. 13. Remove the seat belt buckle from the seat. 14. Remove the seat bottom cover. 15. Remove the seat bottom pad. Installation Procedure 1. Install the seat bottom pad to the seat bottom. 2. Install the seat bottom cover over the pad. Page 258 Seat Adjuster Switch - Front Passenger (w/ 6-Way) Part 1 Seat Adjuster Switch - Front Passenger (w/ 6-Way) Part 2 Page 5993 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement Power Steering Pulley Replacement ^ Tools Required J 25034-C Power Steering Pump Pulley Remover - J 25033-C Power Steering Pump Pulley Installer Removal Procedure 1. Remove the fan clutch. 2. Remove the drive belt. 3. Remove the power steering pump pulley using J 25034-C. Installation Procedure 1. Place the power steering pump pulley on the end of the power steering pump shaft. 2. Install the power steering pump pulley using J 25033-C. 3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 Capacity Specifications Coolant: Capacity Specifications Engine Cooling System Capacity Automatic Transmission 11.1 liters 11.7 quarts Manual Transmission 11.3 liters 11.9 quarts OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 8994 Abbreviations And Meanings - Part 6 Page 5411 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 162 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module (BCM) C3 Part 1 Page 3104 Steps 1-7 Page 5280 C306 (Body Harness To RR Door Harness) (4-Door) Page 9750 Power Window Switch: Service and Repair POWER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power window switch from the trim panel by using a flat-bladed tool in order to pry upward on the leading edge. 2. Disconnect the electrical connector from the switch. Use a small screwdriver in order to press in the retainer springs. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. Page 765 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 5512 Conversion English/Metric Part 1 Specifications Brake Pad: Specifications Pad Minimum Thickness See Note Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. Page 8088 Disclaimer Page 2087 4. Install the water outlet housing mounting bolts. Tighten water outlet housing mounting bolts to 19 Nm (14 ft. lbs.). 5. Install the throttle body bracket to the throttle body. 6. Install the throttle body bracket nuts. Tighten the throttle body bracket nuts to 10 Nm (89 inch lbs.). 7. Fill the cooling system. 8. Inspect for coolant leaks. Page 2478 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8 - 11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8 - 11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 3625 15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. ^ Tighten the accumulator cover retaining bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the control valve body. 18. Install the transmission oil pan and filter. 19. Lower the vehicle. 20. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 2801 4. Disconnect the PCM electrical connectors. Installation Procedure 1. Remove the replacement PCM from the packaging. 2. Check the service number in order to make sure the service number is the same number as the defective PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the PCM electrical connectors screws to 8 N.m (71 lb in). Page 5364 C500 (Body Harness To LF Door Harness) (W/ Power Locks/Windows) Part 2 Page 4905 Abbreviations And Meanings - Part 5 Page 8647 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9634 Abbreviations And Meanings - Part 15 Page 806 Abbreviations And Meanings - Part 15 Page 1151 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .................................................................... R-134a Page 5118 Abbreviations And Meanings - Part 11 Page 1215 Fuse Block - Underhood Connector C1 Part 6 Page 659 IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor can no longer be properly mounted. 7. Perform the following steps in order to complete the first fastener repair: 7.1. Remove and discard the improperly installed rivet. 7.2. Reattach sensor with new rivet. 8. Perform the following steps in order to complete the second fastener repair: 8.1. Remove the improperly installed rivet. 8.2. Enlarge the mounting holes (1) in the lower radiator support to 9.0 mm (0.35 in). 8.3. Insert and properly seat the rivnut. 8.4. Install sensor with screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 8.0 N.m (71 lb in). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the inflatable restraint front end discriminating sensor horizontally to the lower radiator support surface. Ensure that the arrow is pointing toward the front of the vehicle. 3. Install the inflatable restraint front end discriminating sensor mounting rivets (GM P/N 15715058). Page 2736 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Service and Repair Tailgate Striker: Service and Repair Lock Striker Replacement - End Gate (Utility) Removal Procedure Important: Do not remove both endgate striker bolts at the same time in order to prevent the striker backing plate from falling into the body. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt in order to rotate the striker and the spacer (if equipped) away from the lower bolt hole. 3. Install the lower striker bolt. 4. Tighten the lower striker bolt in order to hold the striker backing plate in place. 5. Remove the upper striker bolt. 6. Remove the spacer (if equipped). 7. Remove the striker. Installation Procedure 1. Install the striker. 2. Install the spacer (if equipped). 3. Install the upper striker bolt. Rotate the lower striker bolt until the upper threaded hole is properly aligned in order to ensure that the backing plate is in the correct position. 4. Remove the lower bolt. 5. Rotate the striker and the spacer (if equipped) in order to align the lower threaded hole in the striker backing plate. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the lower striker bolt. Tighten the bolts to 22 N.m (16 lb ft). Page 2937 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 9522 Abbreviations And Meanings - Part 18 Page 8809 2. Install the endgate bellcrank rod to the endgate inside handle assembly. 3. Secure the endgate latch rods to the latch rod clips. 4. Install the endgate cover to the endgate. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the screws that retain the endgate cover to the endgate. Tighten the screws to 1.2 N.m (11 lb in). 6. Install the endgate trim panel. 7. Install the handle to the inside handle assembly. Page 8683 Abbreviations And Meanings - Part 3 Page 3510 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the electrical connector from the vehicle speed sensor. 3. Remove the following parts: ^ The vehicle speed sensor ^ The O-ring seal Installation Procedure 1. Coat a new O-ring seal with a thin film of transmission oil. Notice: Refer to Fastener Notice in Service Precautions. OnStar(R) - Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 1209 Fuse Block - I/P Part 5 Fuse Block - Underhood Connector C1 Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in. 1.52 mm Page 5185 Fuse Block - Underhood Connector C4 Part 1 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 8186 6. Remove the 8 garnish molding screws. 7. Remove the sunroof panel window garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Position the garnish molding to the headliner. 2. Ensure the sunroof switch wiring is positioned properly through the garnish molding. 3. Install one short front screw (1) and install one long rear screw in order to hold the garnish molding (3) in position. 4. Install the remaining screws including the one other short screw next to the motor/actuator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). Page 3641 Band Apply Servo: Service and Repair 2-4 Servo ^ Tools Required J29714-A Servo Cover Depressor Removal Procedure 1. Raise the vehicle. 2. Support the transmission with a suitable jack. 3. Remove the transmission support. 4. Remove the exhaust manifold pipe. 5. Place a drain pan under the vehicle. 6. Lower the transmission just enough to gain access to the oil cooler lines. 7. Disconnect the oil cooler lines, if necessary, to gain access to the 2-4 servo. 8. Remove the oil pan bolt below and to the left of the 2-4 servo cover. 9. Install the J29714-A to the oil pan rail. 10. Tighten the bolt on the J29714-A in order to compress the servo cover. 11. Remove the servo cover retaining ring. 12. Loosen the bolt on the J29714-A to release tension on the servo cover. Page 5084 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 2174 Mass Air Flow (MAF) Sensor Page 5593 Fuse Block - Underhood Connector C2 Part 2 Page 3317 9. Install the distributor cap. 10. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to installation procedure 2 if malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the malfunction indicator lamp (MIL) is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. INSTALLATION PROCEDURE 2 Page 9642 Abbreviations And Meanings - Part 23 Page 6670 High Pressure Safety Valve HVAC: Service and Repair Installation COMPRESSOR PRESSURE RELIEF VALVE INSTALL TOOLS REQUIRED J 43600 ACR 2000 Refrigerant System 1. Clean the valve seat area on the rear head. 2. Lubricate the O-ring of the new pressure relief valve (1) and the O-ring assembly using new 525 viscosity refrigerant oil. 3. Install the new pressure relief valve (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the new valve to.......................9.0 N.m (80 lb ft). 4. Evacuate and recharge the system using the J 43600. 5. Install the A/C compressor to the vehicle. Page 7733 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module (BCM) C3 Part 1 Page 5350 C315 (Body Harness To Passenger Seat Assembly Pigtail Connector) 4-Door with Power Seats) Page 2676 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5138 Registered And Non-Registered Trademarks - Part 4 Page 9813 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module (BCM) C1 Part 1 Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Gage Sensor ............................................................................................................................................................. 30 Nm (22 ft. lbs.) Engine Oil Pressure Gage Sensor Fitting - Plus Required Angle ............................................................................................................. 15 Nm (11 ft. lbs.) Page 7975 Liftglass Release Actuator Front Suspension Suspension Strut / Shock Absorber: Specifications Shock Absorber Lower Bolts (RWD) 22 ft. lbs. Shock Absorber Upper Nut (RWD) 106 inch lbs. Page 6042 Page 9112 Arrows And Symbols Uses various symbols in order to describe different service operations Page 6395 Disclaimer Page 1415 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Page 6376 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Page 5974 1. Install the power steering cooler hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering cooler hose to the power steering cooler. Tighten the power steering cooler hose to the power steering cooler clamp to 2 Nm (18 inch lbs.). 3. Connect the power steering cooler hose to the power steering pump. Tighten the power steering cooler hose to the power steering pump clamp to 2 Nm (18 inch lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the air cleaner assembly. 6. Bleed the power steering system. Page 6037 Page 9150 Registered And Non-Registered Trademarks - Part 1 Page 243 Outside Rearview Mirror Switch Page 1766 17. Remove the bracket for the engine wiring harness from the intake manifold stud. 18. Remove the fuel lines from the fuel meter body assembly. 19. Remove the EVAP canister purge solenoid valve. 20. Remove the studs for the upper intake manifold. 21. Remove the upper intake manifold. 22. Remove the upper intake manifold gasket from the groove. 23. Discard the gasket. Page 6810 9. Verify that the tabs on the lower shroud (1) engage with the tabs on the upper shroud (2). Snap the tabs together. Tighten Tighten the screws to 1.5 N.m (13 lb in). 10. On vehicles with a tilt column, align the tilt lever into the steering column. 11. Slide the tilt lever handle into the steering column until the handle locks into position. 12. Feed the wiring through the steering wheel. 13. Align the steering wheel with the mark on the steering shaft. Install the steering wheel onto the shaft. 14. Install the nut for the steering wheel. Tighten Tighten the nut to 41 N.m (30 lb ft). 15. Install the inflatable restraint steering wheel module. 16. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Page 6640 Evaporator Core: Service and Repair EVAPORATOR CORE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the right fender. 2. Remove the blower motor resistor. 3. Remove the accumulator. 4. Remove the evaporator tube. 5. Remove the evaporator and blower module heat shield mounting screws. 6. Remove the evaporator and blower module heat shield. 7. Remove the evaporator and blower module mounting bolts and nuts. IMPORTANT:Retain the evaporator and blower module heat shield mounting bracket for installation. 8. Remove the evaporator and blower module from the vehicle. 9. Remove the 6 retaining screws holding the evaporator case section to the blower case section. 10. Separate the evaporator case section from the blower case section. 11. Remove the evaporator core from the blower case section. 12. Inspect the seals and replace as necessary. Page 8997 Abbreviations And Meanings - Part 9 Diagrams Fuel Tank Pressure (FTP) Sensor Page 2711 Registered And Non-Registered Trademarks - Part 4 Page 6720 A/C High Pressure Switch Page 7607 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 80 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 6205 11. Remove the torsion bars. Note the exact direction of the forward end and the side of the torsion bar that is being removed. 12. Remove the torsion bar links lower retaining nuts. 13. Remove the torsion bar links from the torsion bar support. Installation Procedure 1. Install the torsion bar links to the torsion bar support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the torsion bar links lower retaining nuts. Tighten the torsion bar links lower retaining nuts to 50 Nm (37 ft. lbs.). Page 934 5. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 6. Line up the square-cut hole in the vane wheel with the camshaft position (CMP) sensor. 7. Remove the two screws that hold the CMP sensor. 8. Discard the screws. Page 7698 Abbreviations And Meanings - Part 26 Page 754 Diagrams Rear Wiper/Washer And Endgate Window Release Switch Page 314 3. Install the electrical connector. 4. Install the knee bolster trim panel. Page 2274 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Diagrams Clockspring Assembly / Spiral Cable: Diagrams Inflatable Restraint Steering Wheel Module Coil C1 (Pigtail To The Inflatable Restraint Steering Wheel Module) Page 3133 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 491 Page 7642 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Service and Repair Front Door Window Regulator: Service and Repair Window Regulator Replacement - Front Door Tools Required J 34940 Rivet Gun Removal Procedure 1. Remove the window. 2. Disconnect the power window motor electrical connector, if equipped. 3. Remove the electrical harness retainers, if equipped. 4. Drill out the rivets that secure the window regulator to the door. 5. Remove the window regulator from the door. 6. Remove the power window motor, if equipped. Installation Procedure 1. Install the power window motor, if equipped. 2. Install the window regulator to the door. 3. Install the rivets that secure the window regulator to the door using J 34940. 4. Connect the electrical connector, if equipped. 5. Connect the electrical harness retainers, if equipped. 6. Install the window. Page 7704 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 5325 C209 (Dome Harness To Body Harness) Part 1 Page 1710 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Important: Do not manually depress the retaining clip when installing the plastic cap. 6. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Inspect and fill the engine oil to the proper level. Page 158 Body Control Module (BCM) C1 Part 3 Page 8575 Seat Lumbar Switch - Driver Part 1 Page 5013 Abbreviations And Meanings - Part 2 Page 1528 1. Install a NEW crankshaft rear oil seal housing gasket. 2. Install the NEW crankshaft rear oil seal housing with the oil seal to the engine block using the following procedure. Important: Do not oil or grease the seal lip or the crankshaft seal area. 2.1. Leave the sleeve in the crankshaft rear oil seal and use the sleeve as a guide to ease the seal lip over the end of the crankshaft. 2.2. Push the crankshaft rear oil seal housing fully onto the crankshaft until the crankshaft rear oil seal housing is against the crankshaft rear oil seal gasket and the engine. 2.3. Remove the sleeve. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nut to the crankshaft rear oil seal housing. Tighten the crankshaft rear oil seal housing bolts and nut to 12 Nm (106 inch lbs.). 4. Install the engine flywheel. 5. Install the oil pan. Page 6105 Registered And Non-Registered Trademarks - Part 1 Page 8982 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 9045 6. Remove the screw at the front of the console. 7. Pull downward on the rear of the console in order to remove the sunroof console from the roof. 8. Disconnect the electrical connectors (1, 5, 6) as needed. 9. Remove the sunroof console. Note: Use caution not to damage or crease the headliner while repositioning. 10. Reposition the front of the headliner down and out of the way of the compass mounting bracket. 11. Remove the screw that retains the sunroof console mounting bracket to the roof. 12. Remove the compass sensor mounting bracket from the vehicle. 13. Remove the front center clip-in retainer from the compass sensor mounting bracket. 14. Install the clip-in retainer on the new compass sensor mounting bracket, P/N 15106819. 15. Trim the headliner as shown above in order to allow clearance for the new compass mounting sensor bracket. Follow the dimensions below for the trimming of the sensor bracket. ^ A = 71 mm (2.8 in) ^ B = 19 mm (0.75 in) ^ C = Center line of headliner ^ D = 9.5 mm (0.375 in) Locations Throttle Position Sensor: Locations Engine, LR Page 9105 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 4638 6. Compress the front caliper piston. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the piston is fully seated in the brake caliper bore. ^ Remove the C-clamp from the caliper. 7. Remove the brake caliper hose bolt from the brake caliper. 8. Remove the 2 metal gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 9. Discard the 2 metal gaskets. 10. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 11. Remove the brake caliper mounting bolts. 12. Remove the brake caliper. 13. Remove the brake pads from the brake caliper. Page 1483 5. Remove the engine camshaft. 5.1. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. 5.2. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings. 5.3. Remove the bolts from the front of the engine camshaft. 5.4. Clean and inspect the camshaft and the bearings. Installation Procedure Important: Whenever a new camshaft is installed, do the following procedures: ^ Change the engine oil. ^ Change the engine oil filter. ^ Add GM Engine Oil Supplement GM P/N 1052367 (Canadian P/N 992869) or the equivalent to the engine oil. 1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, or engine oil supplement GM P/N 1052367 (Canadian P/N 992869) or equivalent to the following components: ^ The engine camshaft lobes ^ The camshaft bearing journals ^ The camshaft bearings 2. Install three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Use the bolts as a handle in order to install the engine camshaft. 4. Remove the 3 bolts from the front of the engine camshaft. Notice: Refer to Fastener Notice in Service Precautions. 5. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the camshaft retainer bolts. Specifications Brake Hose/Line: Specifications Brake Junction Block Bolt 13 ft. lbs. Brake Pipe Fittings 13 ft. lbs. Brake Pipe Fittings to BPMV 15 ft. lbs. Brake Pipe Fittings Master Cylinder 22 ft. lbs. Front Flex Hose to Caliper Bolt 40 ft. lbs. Front Flex Hose Support Clip Nut 16 ft. lbs. Rear Flex Hose to Bracket Bolt 13 ft. lbs. Brake Hose Fitting Bolt (Rear Wheel) 40 ft. lbs. Front Flex Hose Bolt (Front Wheel) 40 ft. lbs. Rear Brake Pipe Fitting 16 ft. lbs. Front Brake Lines to BPMV 22 ft. lbs. Master Cylinder Brake Lines to BPMV 18 ft. lbs. Rear Brake Line to BPMV 18 ft. lbs. Page 8793 Rear Window Wiper Cutout And Liftglass Ajar Jamb Switch (Utility) Page 5937 1. Position the idler arm on the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the idler arm mounting bolts and nut to the frame. Tighten the idler arm mounting bolts and nuts to 108 Nm (79 ft. lbs.). 3. Install the idler arm to the relay rod ball stud. Ensure that the seal is on the stud. 4. Seat the taper using J 29193 or J 29194. Tighten the J 29193 or J 29194 to 82 Nm (60 ft. lbs.). 5. Remove J 29193 or J 29194 from relay rod stud. 6. Install the new nut to the relay rod ball stud. Tighten the relay rod ball stud nut to 47 Nm (35 ft. lbs.). 7. Lower the vehicle. 8. Adjust the front toe. On Vehicle Oil Pan: Service and Repair On Vehicle Oil Pan Replacement Removal Procedure 1. Remove the engine. 2. Remove the oil pan drain plug and drain the engine oil into a suitable container. Important: The low oil level sensor is not reusable. Use a NEW low oil sensor. 3. Remove and discard the engine oil level sensor (if applicable). 4. Remove the oil pan bolts and nuts. 5. Remove the oil pan. Page 8308 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 5603 Fuse Block - Underhood Connector C5 Page 4874 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 6804 Inflatable Restraint Steering Wheel Module Coil C4 (Pigtail To The Body Harness) Page 9165 Driver/Vehicle Information Display: Service and Repair Driver Information Center Replacement (With Sunroof) DRIVER INFORMATION CENTER REPLACEMENT (WITH SUNROOF) REMOVAL PROCEDURE 1. Remove the screw at the front of the console that retains the sunroof console to the roof. 2. Pull downward on the rear of the console in order to remove the sunroof console from the roof. 3. Disconnect the electrical connectors (1, 5, 6) as needed. 4. Remove the screw that retains the sunroof console mounting bracket to the roof. INSTALLATION PROCEDURE 1. Install the electrical connectors (1, 5, 6) as needed. 2. Insert the console mounting tabs into the mounting bracket and push upward on the rear of the console in order to install the console. 3. Install the screw at the front of the console that retains the console to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 1.9 N.m (17 lb in). Page 6107 Registered And Non-Registered Trademarks - Part 3 Page 8486 4. Remove the rosebud clips from the front side door opening frame. 5. Remove the hose from the vehicle. INSTALLATION PROCEDURE 1. Install the sunroof drain hose to the spigot at the front corner of the sunroof. 2. Wrap the left drain hose to the dome lamp wiring harness using electrical tape. 3. Install the 4 rosebud clips on the harness assembly into the left front side door opening frame. Page 2234 Crankshaft Position (CKP) Sensor Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Page 7613 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(tm) sensor is inside the upper right side of the steering column. The Passlock(tm) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(tm) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(tm) sensor in order to help prevent tamper to the system. Passlock(tm) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(tm) sensor will generate a unique Passlock(tm) code. All 10 combinations of the Passlock(tm) sensor have the same part number. However, you cannot simply replace the Passlock(tm) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 1692 8. Discard the oil filter adapter gasket. 9. Remove the oil filter adapter seal (O-ring). 10. Discard the oil filter adapter seal (O-ring). Installation Procedure 1. Install the new oil filter adapter seal (O-ring) into the groove on the oil filter adapter. 2. Install the oil filter adapter and a new oil filter adapter gasket. Notice: Refer to Fastener Notice in Service Precautions. Locations Endgate Harness Routing View Page 4838 6. Remove the negative battery cable. INSTALLATION PROCEDURE 1. Install the negative battery cable. 2. Install the negative battery cable bolt to the block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the negative battery cable bolt to 17 N.m (13 lb ft). 3. Install the negative battery cable bolt to the radiator support. Tighten Tighten the negative battery cable bolt to 9 N.m (80 lb in). Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV1500 ................................................................................................................ ............................................................................................. 2.7L (2.9 Qt) NV3500 ............................ .............................................................................................................................................................. ................... 2.0L (2.2 Qt) Page 1619 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Drive Belt Falls Off Diagnosis Step 1 - 12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked may will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the Page 1649 8. Install the starter, if removed. 9. Lower the vehicle. Page 9461 Page 8510 Sunroof / Moonroof Weatherstrip: Removal and Replacement Sunroof Seal/Molding Replacement (ZRX/EXTREME w/ CF5) Removal Procedure 1. Remove the sunroof window. 2. Remove the seal (2) from the front of the upper frame by pulling upward on the seal. 3. Finish removing the seal from the rear of the mainframe. 4. Completely clean the channel in the mainframe of silicone adhesive and any other debris. A nylon glazing stick or a soft wire brush would be helpful in removing the silicone. Installation Procedure 1. Apply black, non-corrosive silicone adhesive under the entire outside edge of the seal. 2. Insert the new window seal by pressing the seal into the mainframe channel (3). Use a roller-type tool on the seal to aid in the installation of the seal into the channel. 3. Install the sunroof window. 4. Fully close the sunroof and wait 4-6 hours for the silicone to dry. 5. Visually inspect the window and seal in the full open and closed positions. 6. Open the sunroof. 7. Inspect the seal for high spots, correct if needed. Page 1262 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 5386 Splice Pack SP402 Page 1419 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Page 7730 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module (BCM) C2 Part 1 Page 6676 8. Remove the compressor hose assembly from the condenser. 9. Remove the O-ring seal and discard. INSTALLATION PROCEDURE 1. Install a new O-ring seal. 2. Install the compressor hose assembly to the condenser. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the hose to........................28 N.m (21 lb ft). 3. Install the lower radiator hose. 4. Install a new O-ring seal. Page 6775 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 6884 Disclaimer Page 6573 1. Position the clutch rotor and bearing assembly (2) onto the A/C compressor. 2. Position J 33017 and the bearing (1) from J 33013-B directly over the inner race of the bearing. 3. Place the washer (3) onto the body of J 33013-B. 4. Remove the center screw from the body of J 33013-B. 5. Install the center screw into the opposite end of J 33013-B. 6. Back the body of J 33013-B off enough to thread the center screw onto the end of the A/C compressor shaft. 7. Thread the center screw several turns onto the end of the A/C compressor shaft. Do NOT tighten the screw. 8. Hold the center screw with a wrench. 9. Tighten the hex portion of the J 33013-B body several turns. 10. Remove J 33013-B from the clutch rotor and bearing assembly. 11. Press the clutch rotor and bearing (2) onto the nose of the A/C compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9. 12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Make sure that the camphor side of the retaining ring is facing up when the retaining ring is being installed. 13. Install the clutch plate and hub assembly. 14. Remove the A/C compressor from J 41790. 15. Install the A/C compressor into the vehicle. Page 6966 Disclaimer Locations Ignition Control Module: Locations Engine Generator And Starter Specifications Parking Brake Lever: Specifications Park Brake Lever Mounting Bolts 18 ft. lbs. Park Brake Lever Mounting Nut 18 ft. lbs. Page 8154 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 1851 Step 8 Page 528 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 198 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector (3). 2. Remove 2 screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 3. Remove the ignition control module and heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the 2 screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). Page 9012 Abbreviations And Meanings - Part 24 Page 5487 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 2890 Intake Air Temperature (IAT) Sensor 1. Install the IAT sensor by gently pushing the sensor into the air cleaner outlet duct until seated. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Page 9128 Abbreviations And Meanings - Part 6 Page 2114 4. Connect the insulator to the tail pipe hanger. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the muffler to catalytic converter flange nuts. ^ Tighten the muffler to catalytic converter flange nuts to 40 Nm (30 ft. lbs.). 6. Lower the vehicle. Page 3019 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 2498 Body Control Module (BCM) C1 Part 3 Page 7376 Page 5543 Abbreviations And Meanings - Part 22 Page 1793 2. Install the engine oil pressure sensor fitting, if removed. Tighten the engine oil pressure sensor fitting to 15 Nm (11 ft. lbs.). 3. Install the engine oil pressure sensor. Using the J41712, tighten the engine oil pressure sensor to 30 Nm (22 ft. lbs.). 4. Connect the engine oil pressure sensor electrical connector. 5. Install the distributor. 6. Check and adjust engine oil level. Page 6679 2. Install the evaporator tube to the condenser. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the evaporator tube to...........................28 N.m (21 lb ft). 3. Install the lower radiator hose. 4. Install a new O-ring seal. 5. Install the evaporator tube to the evaporator. Tighten Tighten the evaporator tube to.........................28 N.m (21 lb ft). 6. Install the evaporator tube clip to the accumulator. 7. Install the evaporator tube retaining screw. Tighten Tighten the screw to.............................1.9 N.m (17 lb in). 8. Install the battery. 9. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings components using the J 39400-A. Page 272 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. INSTALLATION PROCEDURE Page 5299 C101 (Body Harness To Engine Harness) Part 3 C102 (Body Harness To Engine Harness) Locations Throttle Position Sensor: Locations Engine, LR Page 5220 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 9339 Locations Ignition Control Module: Locations Engine Generator And Starter Page 9791 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Locations SIR Components Page 9181 Disclaimer Page 4566 7. Remove the brake rotor and wheel bearings, 2 wheel drive vehicles only. 8. Inspect the brake rotor. 9. Inspect the brake caliper. 10. Refinish the rotor if necessary. Installation Procedure Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 1. Using the J42450-A, clean the hub flange, 4 wheel drive vehicles. 2. Install the brake rotor, 4 wheel drive shown. Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 6695 Disclaimer Page 5605 Relay Block - Body Part 1 Page 6859 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Page 4634 8. Remove the front brake caliper piston seal. 9. Remove the bleeder valve from the brake caliper body. 10. Clean the following items with denatured alcohol. ^ The bleeder valve ^ The brake caliper body bore ^ The brake caliper piston Important: If the corrosion cannot be removed, replace the brake caliper housing and piston. 11. Using a crocus cloth, clean the corrosion from the brake caliper bore. 12. Dry the parts using non lubricated, filtered compressed air. 13. Replace the brake caliper or the piston if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Pitting in the caliper bore Assembly Procedure Page 1660 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2 - 3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: ^ Engine oil diluted by moisture or unburned fuel mixtures ^ Improper engine oil viscosity for the expected temperature ^ Incorrect or faulty oil pressure gage sensor ^ Incorrect or faulty oil pressure gage ^ Plugged oil filter ^ Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6 psig) minimum, at 1,000 RPM 7.2. 125 kPa (18 psig) minimum, at 2,000 RPM 7.3. 166 kPa (24 psig) minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: ^ Oil pump worn or dirty ^ Malfunctioning oil pump pressure relief valve ^ Oil pump screen loose, plugged, or damaged ^ Excessive bearing clearance ^ Cracked, porous or restricted oil galleries ^ Engine block oil gallery plugs missing or incorrectly installed ^ Broken valve lifters Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 379-427 kPa (55-62 psi) Page 5158 Application Table Part 5 Page 9535 Registered And Non-Registered Trademarks - Part 4 Removal High Pressure Safety Valve HVAC: Service and Repair Removal With RPO Code HT6/HD6/HU6 COMPRESSOR PRESSURE RELIEF VALVE REMOVAL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED J 34992 Compressor Holding Fixture 1. Install the compressor onto the J 34992. 2. Remove the pressure relief valve (5) from the rear head of the compressor. V7 - Direct Mount COMPRESSOR PRESSURE RELIEF VALVE REMOVAL (V7 - DIRECT MOUNT) TOOLS REQUIRED J 41790 A/C Compressor Holding Fixture 1. Remove the A/C compressor from the vehicle. 2. Clamp the J 41790 in a vise and attach the A/C compressor to the J 41790. Page 3755 Disclaimer Page 9472 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 6563 A/C Compressor Clutch Page 6049 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 2906 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Disconnect the MAP sensor harness connector. 3. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor grommet. 5. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Page 5729 C203 (Body Harness To IP Harness) Part 3 Page 7230 Page 3100 Steps 4-5 Page 6791 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Page 797 Abbreviations And Meanings - Part 6 Page 1627 Drive Belt Vibration Diagnosis Step 1 - 11 Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Locations Steering Column Components Page 448 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Page 2965 Automatic Transmission, RH Page 5209 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 5708 C432 (Body Harness To Defogger Grid Harness) Page 8324 WA160E/06 - WA228A/55 Page 1314 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 9690 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 7468 Compact Disc Player (CD): Service and Repair REMOTE CD PLAYER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Replace the CD and plastic bin as a whole assembly. Removing and installing the screws that attach the CD changer to the plastic bin may cause the CD changer to perform improperly. 1. Open the armrest (5) on the center console to reveal the remote CD changer assembly. 2. Remove the 2 front screws (1) and the rear screw (3) that attach the CD changer assembly to the center console. 3. Pull the CD changer assembly vertically out of the center console 4. Disconnect the electrical connector to the CD changer (4). INSTALLATION PROCEDURE 1. Attach the electrical connector to the CD changer. 2. Install the CD changer assembly into the center console. 3. Install the front CD changer assembly retaining screws (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the front CD changer assembly retaining screws to 1.9 N.m (17 lb ft). 4. Install the rear CD changer assembly retaining screw. Tighten Tighten the rear CD changer assembly retaining screw to 2.5 N.m (22 lb ft). Page 2634 Page 9874 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Engine Controls - Excessive Fuel Gauge Fluctuation Fuel Gauge: All Technical Service Bulletins Engine Controls - Excessive Fuel Gauge Fluctuation Bulletin No.: 03-08-49-014A Date: October 02, 2003 TECHNICAL Subject: Fuel Gauge Fluctuates Between E and 1/4 Tank, Goes From 1/4 to Empty Too Quickly, Excessive Empty Fuel Reserve (Reprogram PCM) Models: 2001-2003 Chevrolet Blazer 2001 GMC Envoy 2001-2003 GMC Jimmy Supercede: This bulletin is being revised to add condition information. Please discard Corporate Bulletin Number 03-08-49-014 (Section 08 - Body and Accessories). This bulletin contains three different conditions depending on the model year of the vehicle involved. Condition # 1 (2001 4-Door Only) Some customers may comment that the fuel gauge goes from 1/4 to empty too quickly. Condition # 2 (2002 4-Door Only) Some customers may comment about excessive empty fuel reserve. Condition # 3 (2003 2-Door and 4-Door) Some customers may comment that the fuel gauge fluctuates between E and 1/4 tank. Correction Important: In order to select the correct calibration on some vehicles, you must first identify the cluster part number. This can be done using the Tech 2. DO NOT REMOVE THE CLUSTER. A new service calibration has been released to correct these conditions. Reprogram the PCM using the new service calibration, which was available from Techline starting August 25, 2003 on the TIS2000 version 9.0 or later. This calibration is an electronic calibration and is not available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 3926 13. Ensure that the transmission range selector lever is in the NEUTRAL position. 14. Following the adjustment procedure, install the range selector cable (2) to the range selector cable lever ball stud (1). Refer to Automatic Transmission Range Selector Cable Adjustment. 15. Install the positive assurance pin to the bracket. 16. Install the transfer case shield, if equipped. Refer to the appropriate procedure: ^ Transfer Case Shield Replacement in Transfer Case-NVG 233-NP1 ^ Transfer Case Shield Replacement in Transfer Case-NVG 236-NP8 17. Lower the vehicle and check for proper operation. Repeat the adjustment procedure if necessary. Refer to Automatic Transmission Range Selector Cable Adjustment. Page 2759 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 5679 C211 (Steering Column Harness To Body Harness) Part 4 Page 4373 Page 9134 Abbreviations And Meanings - Part 12 Page 5892 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer General Information Vehicle Lifting: Service and Repair General Information LIFTING AND JACKING THE VEHICLE CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 8596 Tighten Tighten the bolts to 24 N.m (18 lb ft). 8. Pull the pad and cover back over the seat frame. 9. Install the pad and cover to seat with J-strips (1). 10. Install the spring (2) to the seat adjuster rail. 11. Install the seat back recliner handle. 12. Install seat in the vehicle. Seat Back Replacement - Front (Bench Seat) SEAT BACK REPLACEMENT - FRONT (BENCH SEAT) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the recliner assembly. 3. Remove the seat back pivot bolt. 4. Remove the seat back from the lower frame. INSTALLATION PROCEDURE Locations Seat Switches Page 4839 4. Install the negative battery cable bolt to the frame. Tighten Tighten the negative battery cable bolt to 9 N.m (80 lb in). 5. Lower the vehicle. 6. Connect the negative battery cable. Specifications Steering Wheel: Specifications \ \ Steering Wheel to Steering Shaft Nut 30 ft. lbs. Page 8668 Equivalent - Decimal And Metric Part 2 Page 3073 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and you hear heavy knocking, your engine needs service. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Don't use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage wouldn't be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Remove alignment rack floating plate pins. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) for all vehicles except pickups with options QZ8 and V4A to be considered correct. Pickups with options QZ8 and V4A should be O mm to be considered correct. 1. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and lowest measurements. Z Height Adjustment Page 9186 Page 1719 6. Remove the oil pan gasket. 7. Discard the oil pan gasket. 8. Clean all sealing surfaces on the engine and the oil pan. Installation Procedure Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. 1. Apply a 5 mm (0.197 inch) wide and 25 mm (1.0 inch) long bead of adhesive GM P/N 12346141 or equivalent to both the right and left sides of the engine front cover to engine block junction at the oil pan sealing surfaces. 2. Apply a 5 mm (0.197 inch) wide and 25 mm (1.0 inch) long bead of adhesive GM P/N 12346141 or equivalent to both the right and left sides of the crankshaft rear oil seal housing to engine block junction at the oil pan sealing surfaces. Important: Always install a NEW oil pan gasket. The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. Page 5472 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5849 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 1056 2. Install the evaporator tube to the condenser. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the evaporator tube to...........................28 N.m (21 lb ft). 3. Install the lower radiator hose. 4. Install a new O-ring seal. 5. Install the evaporator tube to the evaporator. Tighten Tighten the evaporator tube to.........................28 N.m (21 lb ft). 6. Install the evaporator tube clip to the accumulator. 7. Install the evaporator tube retaining screw. Tighten Tighten the screw to.............................1.9 N.m (17 lb in). 8. Install the battery. 9. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings components using the J 39400-A. Page 1982 1. Install the fan blade to the fan clutch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan blade mounting bolts. Tighten the bolts to 33 Nm (24 ft. lbs.). 3. Install the fan clutch assembly to the water pump using the J 46406. Tighten the fan clutch to 56 Nm (40 ft. lbs.). 4. Install the upper fan shroud. Service and Repair Front Door Exterior Handle: Service and Repair Door Handle Replacement - Front Outside Removal Procedure 1. Close the window. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the outside door handle screw access hole plug. 5. Remove the outside door lock rod from the handle (2). 6. Remove the outside door handle rod from the handle (1). 7. Remove the screws that retain the outside door handle to the door panel. 8. Remove the outside door handle from the door. 9. Remove and retain the lock cylinder from the outside door handle. Installation Procedure 1. Install the lock cylinder to the outside door handle. 2. Install the outside door handle to the door. Notice: Refer to Fastener Notice in Service Precautions. Page 9085 Page 2751 Transmission Range Switch (W/ A/T) Page 8487 4. Install the 3 rosebud clips on the right drain hose into the right front side door opening frame. 5. Insert the hose through the hole in the outer sheet metal until the paint mark on the hose is visible. The hole is located above the front door top hinge. 6. Install the headliner. Page 796 Abbreviations And Meanings - Part 5 Page 3747 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 1792 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the sensor and Distributor before removal. Do not allow debris to enter the engine. 1. Remove the distributor. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor using the J 41712. Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 4. Remove the engine oil pressure sensor fitting, if necessary. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the fitting and/or the engine oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. Page 4897 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 9836 Abbreviations And Meanings - Part 22 Page 6580 8. Install the J 8433 onto the A/C compressor clutch coil (1) and tighten the puller leg bolts. 9. Tighten the center forcing screw J 8433-3 of the J 8433 against the J 33023-A to remove the A/C compressor clutch coil from the A/C compressor. 10. Remove the J 8433-3, the J 33023-A, the J 33025 and the J 8433. Page 9749 Window Switch - RR Page 5669 C203 (Body Harness To IP Harness) Part 10 Page 5271 C229 (Body Harness To Dome Harness) Page 1208 Fuse Block - I/P Part 4 Page 4002 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the electrical connector from the sensor. 4. Remove the bolt (2). 5. Using a twisting and pulling motion, remove the vehicle speed sensor (1) from the case. 6. Remove and discard the O-ring seal (3). Installation Procedure 1. Install the new O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with clean transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Remove the drain pan. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 5008 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Service and Repair Front Door Window Motor: Service and Repair Motor Replacement - Power Window Removal Procedure Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 1. Remove the window regulator. 2. Drill a hole through the window regulator and the sector gear. 3. Install a bolt and a nut through the hole in order to lock the sector gear in position. 4. Drill out the rivets that secure the power window motor to the window regulator. 5. Remove the power window motor from the window regulator. Installation Procedure 1. Install the power window motor to the window regulator. Important: Remove the nut and the bolt that were used in order to secure the sector gear in position. 2. Install the rivets in order to secure the power window motor to the window regulator. 3. Install the window regulator. Page 9778 Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 6132 10.1. Disconnect the upper ball joint from the steering knuckle. 10.2. If you find any looseness or can twist the stud with your fingers, replace the upper ball joint. Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Remove alignment rack floating plate pins. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) for all vehicles except pickups with options QZ8 and V4A to be considered correct. Pickups with options QZ8 and V4A should be O mm to be considered correct. 1. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and lowest measurements. Z Height Adjustment Page 9667 Page 2675 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4513 1. Install the new bushing and sleeves. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front brake caliper bracket mounting bolts, lower shown. Tighten the brake caliper mounting bracket bolt to 180 Nm (133 ft. lbs.). 3. Install the brake pad assembly. 4. Install the tire and wheel assembly. 5. Lower the vehicle. Refer to Vehicle Lifting. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6 and 7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the brake master cylinder to the proper level. Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Page 8354 WA900J/59 - WA9260/74 Page 3365 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Page 8257 Front Passenger Door Shown, Driver Similar Locations Steering Column Components Page 3591 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SM Caution In Service Precautions. 1. Disable the SIR system. 2. Remove the steering column trim covers. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. Page 4233 Shifter M/T: Service and Repair NV 3500 Shift Tower Replacement Shift Tower Replacement Removal Procedure Important: ^ Ensure that the shift lever is positioned into the mechanical third or fourth gear prior to removal of the shift housing from the transmission. The transmission must remain in this slate when the shift housing is removed. ^ Do not disassemble the transmission shift housing. Internal parts for this shift housing are not available. Opening the shift housing voids the warranty. ^ When removing the shift housing from the transmission, use the exposed bolts on the base of the housing. ^ If equipped, remove the 3 console nuts and console. 1. Remove the shift lever from the shift tower. DO NOT remove the shift lever adjusting nut. 2. Remove the screws securing the boot to the panel. 3. Remove the boot from the shift tower. 4. Remove the shift tower housing bolts. 5. Remove the shift tower housing from the transmission. Installation Procedure Page 1580 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Remove the PCV tube from the air cleaner outlet duct and the valve rocker arm cover. 2. Disconnect the spark plug wires from the spark plugs for the right side of the engine. 3. Remove the Evaporative Emission (EVAP) canister purge solenoid valve. 4. Unfasten the heater hose retainer above the valve rocker arm cover. 5. Move and secure the heater hoses aside. 6. Remove the bolt (3) holding the engine wiring harness bracket to the generator. 7. Disconnect the Crankcase Position (CKP) sensor electrical connector (2). 8. Move and secure the engine wiring harness aside. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 4922 Abbreviations And Meanings - Part 22 Page 8357 WA9539/47 - WA9539/47 Page 260 Seat Adjuster Switch - Driver C1 (w/ 8-Way, w/o Memory) Part 2 Seat Adjuster Switch - Front Passenger C1 (w/ 8-Way, w/o Memory) Part 1 Page 822 Registered And Non-Registered Trademarks - Part 4 Page 7263 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 6816 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Page 9715 Abbreviations And Meanings - Part 5 Page 5725 C200 (IP Harness To Body Harness) Page 8749 Seat Adjuster Switch - Front Passenger (w/ 6-Way) Part 1 Seat Adjuster Switch - Front Passenger (w/ 6-Way) Part 2 Page 5563 Location View Page 1354 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 2871 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 6361 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Over spray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Page 9156 Driver Information Center (DIC) C1 (w/ Trip Computer) Part 2 Page 4969 Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Removal Procedure 1. Remove the rotor. 2. Remove the wheel stud. ^ Press the stud out using an arbor press. ^ Do not damage the wheel mounting surface on the wheel hub flange. Installation Procedure 1. Install the stud into the hole in the wheel hub. 1.1. Start the serrated stud into the hole in the wheel hub by tapping lightly with a hammer. 1.2. The stud must be square with the wheel hub before pressing on the arbor press. 2. Install the rotor. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 437 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 4873 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 271 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. 2. Install the electrical connector to the switch. 3. Install the trim panel to the seat with 3 screws. 4. Install the seat to the vehicle. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the seat from the vehicle. Page 1622 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Step 1 - 15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the Page 1229 Fuse Block - Underhood Connector C5 Page 8446 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator SYNCH. RPO Code Zrx/Extreme W/CF5 SUNROOF MOTOR/ACTUATOR SYNCHRONIZATION (ZRX/EXTREME W/ CF5) TIMING PROCEDURE 1. Open the window at least 2 inches from the front of the sunroof. If the sunroof will not open, refer to Sunroof Manual Operation (ZRX/EXTREME w/ CF5). 2. Remove the motor. 3. Place your hands on the front edge of the window and gently push both sides to the full open position. Take care to move both sides of the window at the same time. Verify that the leading edge of the window panel is parallel with the rear edge of the sunroof mainframe. 4. Check the screws on the drive tube retainer plates (the gold colored screw located behind the motor block). If loose, check or re-insert the ends of the cable drive and return the tubes into place. Apply Loctite® Blue, GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the screw threads prior to installing the screw. 5. Install the motor. 6. Test the function of the sunroof through several cycles. Page 2704 Abbreviations And Meanings - Part 24 Page 2264 Engine Harness Rear (4.3L) Page 8968 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 8582 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. 2. Connect the electrical connector to the switch. 3. Install the trim panel to the seat with the 3 screws. 4. Install the seat to the vehicle. Page 2441 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 1378 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 5762 C307 (Body Harness To RR Door Harness) (4-Door) Page 5412 Relay Box: Service and Repair Instrument Panel Electrical Center or Junction Block INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 3557 Shift Interlock Solenoid: Diagrams W/Floor Shift W/ Column Shift Page 3624 10. Install the spacer plate support and the spacer plate support retaining bolts. ^ Tighten the spacer plate support retaining bolts to 11 Nm (97 inch lbs.). 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. 13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. 14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover. Page 6542 Blower Motor Resistor Locations Seat Belt Components Page 6438 NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the driver side air distributor duct screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel. Page 7661 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Locations Throttle Position Sensor: Locations Engine, LR Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or contamination. Page 8950 Page 5200 Application Table Part 2 Page 5477 Testing and Inspection Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids Inspect the connectors at the BCM, and all other circuit connecting points for an intermittent condition. Inspect the circuit wiring for an intermittent condition. If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Page 910 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Page 2113 5. Disconnect the insulator from the muffler and tail pipe hanger. 6. Remove the muffler from the vehicle. Installation Procedure 1. Install the muffler and NEW gasket to the vehicle. 2. Connect the insulator to the muffler and tail pipe hanger. 3. Connect the insulators to the muffler hanger (4-door utilities). Page 5440 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 9713 Abbreviations And Meanings - Part 3 Page 3507 Page 4170 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.03-0.13 mm (0.001-0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 9532 Registered And Non-Registered Trademarks - Part 1 Page 5168 Fuse Block - I/P Part 4 Page 5486 Testing and Inspection Tow/Haul Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids Inspect the connectors at the BCM, and all other circuit connecting points for an intermittent condition. Inspect the circuit wiring for an intermittent condition. If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Page 5841 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 3184 Steps 3-5 Page 1194 Fuse: Application and ID Underhood Fuse Block Fuse Block - Underhood Details (Uplevel Utility) Application Table Part 1 Service and Repair Windshield Washer Reservoir: Service and Repair WASHER PUMP/RESERVOIR REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the hood. 2. Remove the washer solvent from the solvent container. 3. Disconnect the electrical connectors from the washer pumps. 4. Disconnect the hoses from the washer pumps. 5. Remove the screw retaining the solvent container to the vehicle. 6. Remove the solvent container from the vehicle. Page 8066 1. Install the transmission support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission support to the frame nuts, bolts, and reinforcements, utilities. Tighten the transmission support to the frame nuts to 54 N.m (40 lb ft). 3. Install the transmission support to the frame nuts, bolts, and reinforcement, 4.3 L pickup. Tighten the transmission support to the frame nuts to 54 N.m (40 lb ft). 4. Install the transmission support to the frame nuts, bolts, and reinforcement, 2.2 L. Tighten the transmission support to the frame nuts to 54 N.m (40 lb ft). Page 3314 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove air cleaner assembly. 3. Remove the spark plug wires from the distributor cap. - Twist each spark plug boot 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 4. Remove the electrical connector from the base of the distributor. 5. Remove the two screws that hold the distributor cap to the housing. 6. Discard the screws. 7. Remove the distributor cap from the housing. 8. Use a grease pencil in order to note the position of the rotor in relation to the distributor housing (1). 9. Mark the distributor housing and the intake manifold with a grease pencil. Page 8962 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 8351 WA8624/50 - WA8624/50 Page 9966 Windshield Washer Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Use a flat-bladed tool in order to pry the switch away from the instrument panel. 3. Disconnect the electrical connectors as necessary. INSTALLATION PROCEDURE 1. Connect the electrical connectors as necessary. 2. Install the switch to the instrument panel. 3. Connect the negative battery cable. Page 8475 10. Remove the left and right upper trim and lay it down inside the vehicle as seen in the illustration above. 11. Lower the headliner in order to gain access to the rear sunroof drain hoses. 12. Detach the top drain hose fastener from the roof by pulling out the clear colored clip from the body. Leave the hose unattached to the body at this clip. 13. Reroute the hoses as seen in the illustration above. 14. Raise the headliner and install the left and right upper trim. 15. Install the screw that retains the trim (left side only). Tighten Tighten the trim screw to 1.9 N.m (17 lb in). 16. Install the spare tire and holder if the tire is located inside the vehicle. 17. Install the jack assembly and the cover. 18. Reconnect the cargo lamp connector and install the rear upper garnish trim. 19. Install the end gate sill plate. Cooling System - Rubbing/Scraping Noise on Turns Fan Shroud: Customer Interest Cooling System - Rubbing/Scraping Noise on Turns Bulletin No.: 03-06-02-006 Date: July 30, 2003 TECHNICAL Subject: Rubbing/Scraping Noise During Turns (Reposition Cooling Fan Shroud) Models: 2003 Chevrolet Blazer, S-10 2003 GMC Jimmy, Sonoma with 4.3L V6 Engine (VIN X RPO LU3) Condition Some customers may comment on a rubbing/scraping noise during turns, more commonly left turns. Cause This sound resembles a tire rubbing against the inner tender, but may actually be the engine cooling fan contacting the fan shroud. Correction 1. Loosen the three upper cooling fan shroud bolts. 2. Reposition the shroud so there is a equal amount of clearance all the way around the fan and the shroud. 3. Tighten the upper cooling tan shroud bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge 0.80 kg 1.75 lb. Page 3398 Page 3037 1. Place the accelerator pedal assembly over the mounting studs and onto the mounting surface. 2. Install the accelerator pedal mounting nuts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the accelerator pedal mounting nuts to 9 N.m (80 lb in). 3. Lift upward on the accelerator pedal. 4. Insert the cable through the pedal lever slot. 5. Press the retainer into the lever hole until fully seated. 6. Check the accelerator pedal for free movement by depressing and releasing the pedal several times. IMPORTANT: The pedal must operate freely without binding through the full range of pedal movement. 7. Install the left closeout/insulator panel. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 8758 Seat Lumbar Switch - Driver Part 2 Seat Lumbar Switch - Front Passenger Part 1 Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The Malfunction Indicator Lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A Diagnostic Trouble Code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 9807 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 1816 sprocket. 7.3. Remove the bolt that was installed in the end of the crankshaft. 7.4. Install the engine front cover. Page 3392 Disclaimer Page 5093 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 4248 Transmission Mount: Service and Repair NV 3500 Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission mounting bolts. 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure Weatherstrip Replacement - Rear Door Window Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Open the rear side door window. 2. Remove the rear side door window weatherstrip. Start the at butt joint and pull the weatherstrip from the window opening. Installation Procedure 1. Install the rear side door weatherstrip. 2. Locate the butt joint at the bottom center of the window opening and set the weatherstrip around the window opening. Page 7608 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer General Information Vehicle Lifting: Service and Repair General Information LIFTING AND JACKING THE VEHICLE CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 6459 Page 6768 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Vantage Inspection - Off Vehicle Inspection Procedure Notice: Vehicles involved in accidents that result in any of the following kinds of damage or situations, may also have a damaged or misaligned steering column: ^ Frame damage ^ Major body damage ^ Sheet metal damage ^ If the steering column has been impacted ^ If the supplemental inflatable restraints system was deployed ^ Check the capsules on the steering column bracket assembly: all must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. ^ Check for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. If measured dimensions are not within specifications, a new jacket must be installed. Notice: Before the shaft is rotated, remove the inflatable restraint coil assembly from the steering column and allow it to hang freely. Failure to do so may damage the coil assembly. Page 6570 Compressor Clutch Bearing: Service and Repair Installation With RPO Code HT6/HD6/HU6 CLUTCH ROTOR AND/OR BEARING INSTALL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED - J 6083 External Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 29886 Driver Handle - J 21352-A Support Block - J 9481-A Bearing Installer - J 33019 Pulley Bearing Staking Tool - J 33017 Pulley and Bearing Assembly Installer - J 8433-1 Puller Bar - J 8433-3 Forcing Screw - J 34992 Compressor Holding Fixture 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation. NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 2. Use the following tools in order to align the new bearing squarely with the hub bore: - The J 41552 - The J 9481-A - The J 29886 3. Drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing, if used as shown. Page 4319 Shift Interlock Solenoid: Diagrams W/Floor Shift W/ Column Shift Page 8187 5. Install the 8 sunroof panel window garnish molding screw covers. 6. Position the sunroof switch (4) to the motor/actuator trim cover (5). 7. Locate switch to cover in order to secure. 8. Position motor/actuator trim cover to the sunroof panel window garnish molding. 9. Install the motor/actuator trim cover screw (2). Tighten Tighten the screw to 1.5 N.m (13 lb in). 10. Install the motor/actuator service cover. Page 2991 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID The EVAP vent solenoid controls fresh airflow into the EVAP canister. The solenoid is normally open. The control module commands the solenoid ON, closing the solenoid during some EVAP tests, allowing the system to be tested for leaks. IP Fuse Block Details Fuse Block: Application and ID IP Fuse Block Details Location View Application Table Part 1 Page 8319 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Page 6012 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 2938 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 5204 Application Table Part 3 Page 5652 C108 - Electric Shift Transfer Case Extension Harness To Body Harness, NP1 Specifications Vacuum Brake Booster: Specifications Vacuum Booster Mounting Nut 30 ft. lbs. Brake Assist Tandem Diaphragm JC1/JM3 10.24 in. Page 9787 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 9158 Driver Information Center (DIC) C2 (w/ Short Console) Page 9548 Steps 13-17 Page 7481 Speaker - LR Door (4-Door Utility) Page 1189 Location View Page 5135 Registered And Non-Registered Trademarks - Part 1 ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Important: ^ Use the two-person bleed procedure under the following conditions: Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. Do not reuse brake fluid that is used during bleeding. - Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. 2. Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially filled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 4664 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Remove the fluid level sensor (1). Use a needle nose pliers in order to compress the locking tabs at the opposite side of the master cylinder. Installation Procedure 1. Install the fluid level sensor (1) until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Page 8453 Sunroof Switch C2 Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 2457 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. Page 2918 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 2294 Engine Harness Rear (4.3L) Page 5078 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Brake Pads Replacement - Front (Single Piston Caliper) Brake Pad: Service and Repair Brake Pads Replacement - Front (Single Piston Caliper) Brake Pads Replacement - Front (Single Piston Caliper) Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Important: The following service procedure is for the vehicles that have had the brake rotor retainers removed. 6. Install and hand tighten a wheel lug nut to hold the brake rotor in place. 7. Compress the front caliper piston. Page 9598 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 2211 Disclaimer Page 2152 Powertrain Control Module (PCM) Connector C2 Part 4 Page 287 Sunroof Opening Position Switch Page 8333 WA5322/33 - WA534F/54 Page 7731 Body Control Module (BCM) C2 Part 2 Page 6112 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Page 4166 The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 6206 3. Install the torsion bars in relation to where the bars were removed. 4. Install the torsion bar support to the frame. 5. Install the torsion bar support link upper mounting bolts to the frame. 6. Install the torsion bar support link upper mounting nuts. Tighten the torsion bar support link upper mounting nuts to 65 Nm (48 ft. lbs.). 7. Install the adjustment arm to the torsion bar support and slide the torsion bar rearward until the torsion bar fully engages the adjustment arm. 8. Install J 36202 to the adjustment arm and the crossmember. 9. Increase the tension on the adjustment arm in order to load the torsion bar. Important: Tighten the adjuster bolt the same amount of turns that were required to remove the adjuster bolt during removal. 10. Install the adjuster bolt and adjuster nut 11. Remove J 36202 from the adjustment arm and crossmember. 12. Lower the vehicle. 13. Check the wheel alignment. Page 3071 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Page 5221 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 3414 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 4292 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 5595 Fuse Block - Underhood Connector C2 Part 4 Page 7240 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 7280 Abbreviations And Meanings - Part 6 Page 1414 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 6700 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. See: Specifications/Capacity Specifications Page 9866 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 2666 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 5610 Relay Block - Body Part 6 Page 3442 Shift Interlock Solenoid: Diagrams W/Floor Shift W/ Column Shift Page 1771 15. Install the accelerator and cruise control cable bracket to the throttle body. 16. Install the accelerator and cruise control cable bracket nuts. Tighten the accelerator and cruise control cable bracket nuts to 9 Nm (80 inch lbs.). 17. Install the accelerator control cable bracket to the throttle body and the intake manifold. Tighten the accelerator control cable bracket studs and nuts to 12 Nm (106 inch lbs.). 18. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover. 19. Position the engine wiring harness. 20. Install the wire harness clip to the accelerator cable bracket. 21. Connect the following electrical connectors: Page 8537 Memory Seat Module - Driver C2 Part 2 Page 159 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module (BCM) C2 Part 1 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Specifications Drive Pulley: Specifications Fan and Water Pump Pulley Bolt ............................................................................................................................................................. 25 Nm (18 ft. lbs.) Water Pump Pulley Bolts ....................................................................................... ................................................................................... 25 Nm (18 ft. lbs.) Page 4168 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling Page 5460 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 7113 Abbreviations And Meanings - Part 6 Page 2432 Ignition Cable: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. - Twist the boots » turn before removing the boots. - Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. - Twist each spark plug boot 1/2 turn. - Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE 1. Install the spark plug wires at the distributor. NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Powertrain Control Module (PCM) Connector C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C1 Powertrain Control Module (PCM) Connector C1 Part 1 Page 9081 Page 8611 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 9644 Abbreviations And Meanings - Part 25 Page 8670 Arrows And Symbols Uses various symbols in order to describe different service operations Page 2396 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Page 4871 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 9751 2. Install the power window switch to the trim panel by pressing down. Ensure that the retainers lock into place. Page 854 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Conditions For Wheel Replacement Wheels: Testing and Inspection Conditions For Wheel Replacement Replacement Wheels Description Replace the wheel if any of the following conditions exist: ^ The wheel exhibits excessive runout. ^ The wheel is bent. ^ The wheel is cracked. ^ The wheel is severely rusted. ^ The wheel is severely corroded. Important: Air leaks caused by porosity on aluminum wheels are repairable. ^ The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable if any of the following conditions exist: ^ The wheel has elongated bolt holes. ^ The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Page 3458 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 6678 Hose/Line HVAC: Service and Repair Evaporator Tube EVAPORATOR TUBE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the battery. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube retaining screw. 4. Remove the evaporator tube clip from the accumulator. 5. Remove the evaporator tube from the evaporator. 6. Remove the O-ring seal and discard. 7. Remove the lower radiator hose. 8. Remove the evaporator tube from the condenser. 9. Remove the O-ring seal. INSTALLATION PROCEDURE 1. Install a new O-ring seal. Page 7946 Hood Latch: Service and Repair Hood Latch Support Replacement Hood Latch Support Replacement Removal Procedure 1. Open and support the hood. 2. Remove the grille. 3. Remove the primary latch assembly. 4. Remove the bolts that retain the primary hood latch support bracket to the radiator support. 5. Remove the primary hood latch support from the vehicle. 6. Mark the position of the nuts that retain the latch mounting bracket to the support bracket. 7. Remove the primary latch mounting bracket from the support bracket bolts. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the bolts that retain the primary latch mounting bracket to the support bracket. Tighten the primary latch mounting bracket to the support bracket bolts to 25 N.m (18 lb ft). Distributor Ignition (DI) System Description Engine Control Module: Description and Operation Distributor Ignition (DI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: The Throttle Position (TP) sensor - The Engine Coolant Temperature (ECT) sensor - The Mass Airflow (MAF) sensor - The Intake Air Temperature (IAT) sensor - The Vehicle Speed Sensor (VSS) - The transmission gear position or range information sensors - The engine Knock Sensors (KS) Page 450 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 5771 C412 (Endgate Harness To Body Harness) Page 9639 Abbreviations And Meanings - Part 20 Page 2657 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 5898 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is louver than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height. The front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at thigh speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 3742 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 8330 WA519F/12 - WA526F/72 Page 3266 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 5268 C219 (Left Inflatable Restraint Discriminating Sensor Jumper Harness to the Right Sensor Harness) (With RPO Code K18) Page 8612 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 5792 Splice Pack SP201 Part 1 Page 4387 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the electrical connector from the vehicle speed sensor. 3. Remove the following parts: ^ The vehicle speed sensor ^ The O-ring seal Installation Procedure 1. Coat a new O-ring seal with a thin film of transmission oil. Notice: Refer to Fastener Notice in Service Precautions. Page 5902 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angle Description Thrust Angles Description The front wheels aim or steer the vehicles. The real wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 8799 Air Dam: Service and Repair Air Deflector Replacement - Front Bumper Fascia (Optional) Air Deflector Replacement - Front Bumper Fascia (Optional) Removal Procedure 1. Remove the front bumper from the vehicle. 2. Remove the license plate bracket, if equipped. 3. Remove 6 push-in retainers securing the deflector to the bumper. 4. Pull the air deflector retainers from the slots in the bumper. 5. Remove the deflector from the vehicle. 6. Remove the fog lamps from the deflector, if equipped. Refer to the appropriate procedure in Lighting Systems: * Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement * Fog Lamp Replacement - Front (Xtreme) Installation Procedure 1. Install the fog lamps to the deflector, if equipped. * Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement * Fog Lamp Replacement - Front (Xtreme) 2. Install the deflector to the vehicle. Ensure that the snap retainers lock into position. 3. Install 6 push-in air deflector retainers securing the deflector to the bumper. 4. Install the license plate bracket, if equipped. 5. Install the front bumper to the vehicle. Page 637 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Page 8005 Trunk / Liftgate Shock / Support: Service and Repair Support Cable Replacement - End Gate SUPPORT CABLE REPLACEMENT - END GATE (UTILITY) REMOVAL PROCEDURE 1. Safely support the endgate in the open position. 2. Remove the bolts that retain the endgate supports to the endgate. 3. Remove the endgate supports from the vehicle. INSTALLATION PROCEDURE 1. Install the endgate supports to the vehicle. 2. Install the bolts that retain the endgate supports to the endgate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 3 N.m (25 lb in) 3. Close the endgate. Page 3960 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 7314 Steps 10-11 Page 5114 Abbreviations And Meanings - Part 7 Page 3969 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 585 Throttle Position (TP) Sensor Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 8223 1. Install the door lock cylinder to the outside door handle. 2. Install the door lock cylinder retainer. 3. Install the outside door handle. Page 9494 Arrows And Symbols Uses various symbols in order to describe different service operations Page 1940 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 1364 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Important: ^ Use the two-person bleed procedure under the following conditions: Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. Do not reuse brake fluid that is used during bleeding. - Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. 2. Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially filled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 4555 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Front Brake Rotor Replacement - Front Tools Required ^ J42450-A Wheel Hub Resurfacing Kit Removal Procedure Important: The following service procedures applies to both 4 wheel and 2 wheel drive vehicles. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Notice: Refer to Brake Caliper Notice in Service Precautions. 3. Remove the brake caliper, 2 wheel drive vehicles. 4. Remove the brake caliper and mounting bracket, 4 wheel drive. Page 8737 Power Mirror Switch: Service and Repair Power Folding Outside Mirror Switch POWER FOLDING OUTSIDE MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the folding outside mirror switch by carefully using a flat-bladed tool in order to pry up on the leading edge. 3. Remove the accessory switch panel from the armrest. Use a flat-bladed tool in order to carefully pry the cover up at the front leading edge leaving the electrical connections connected. 4. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Install the power accessory switch mounting panel to the armrest. Ensure that the retainers lock into place. 3. Install the power folding mirror switch to the door trim panel. Ensure that the retainers lock into place. 4. Connect the battery negative cable. Page 6807 9. Remove the lower shroud (2). 10. Remove 2 TORX(r) head screws (2) from the upper shroud (1). 11. Remove the upper shroud (1). 12. Remove the wire harness straps from the steering wheel column wire harness. 13. Remove the retaining ring (3). 14. Remove the SIR coil (4) from the steering shaft. 15. If replacing, discard the SIR coil. INSTALLATION PROCEDURE 1. To install the SIR coil, perform the following procedure: 1.1. Aim the wheels straight ahead. Page 8420 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the straps that retain the wiring harness. 3. Disconnect the electrical connectors, as needed. 4. Slide the sunroof control module (2) to the right in order to remove the sunroof control module from the vehicle. INSTALLATION PROCEDURE 1. Slide the sunroof control module (2) to the left in order to install the sunroof control module to the vehicle. 2. Connect the electrical connectors, as needed. 3. Install the straps that retain the wiring harness. 4. Install the headliner. Page 1092 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 6104 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 6169 Stabilizer Link: Specifications Stabilizer Bar Lower Link Nut (4-Door Utility) 42 ft. lbs. Stabilizer Bar Lower Link Nut (Pickups and 2-Door Utility) 50 ft. lbs. Stabilizer Bar Upper Link Nut (4-Door Utility) 50 ft. lbs. Stabilizer Bar Upper Link Nut (Pickups and 2-Door Utility) 25 ft. lbs. Stabilizer Clamp U-bolt Nuts 44 ft. lbs. Page 5600 Fuse Block - Underhood Connector C4 Part 2 Page 1578 7. Install the PCV valve hose assembly to the valve rocker arm cover. 8. Connect the ECT sensor electrical connector. 9. Install air cleaner outlet duct. Diagrams Power Seat Motor Position Sensor: Diagrams Seat Front Vertical Position Sensor - Driver (w/ Memory) Page 6487 Equivalent - Decimal And Metric Part 2 Page 1193 Application Table Part 3 Page 2950 Throttle Position (TP) Sensor Page 9840 Abbreviations And Meanings - Part 26 Page 4429 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 9251 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 9842 Registered And Non-Registered Trademarks - Part 1 Page 3406 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 5654 C116 C1 (Active Transfer Case Harness To Engine Harness) Page 8489 1. Connect the rear drain hose from the drain exit located at the rear of the sunroof on either side. 2. Install the rosebud clips securing the drain hose to the vehicle. 3. Install the end of the drain hose into the sill opening. 4. Install the headliner. Page 5383 Splice Pack SP204 Part 1 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Locations Floor Pedals Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Connector Views Windshield Wiper Motor Page 3211 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Page 4026 Page 8125 each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. Page 4095 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Page 1450 1. Start the new stud into the axle flange hole by pressing firmly with your hand. 2. Install a washer and thread the lug nut on the wheel stud with the flat side of the lug nut to the vehicle. 3. Tighten the lug nut in order to draw the wheel stud into the rear of the flange. 4. Remove the lug nut and washers from the wheel stud. 5. Install the brake drum. 6. Install the tire and the wheel. 7. Lower the vehicle. (Rear Disc Brakes) Wheel Stud Replacement (Rear Disc Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Page 2428 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Page 5566 Application Table Part 2 Page 5790 Splice Pack SP200 Part 1 Page 596 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Description and Operation Door Switch: Description and Operation DOOR LATCH, DOOR JAMB SWITCHES The theft deterrent system uses the door latch switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. Page 9944 Wiper Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Use a flat-bladed tool in order to pry the switch away from the instrument panel. 3. Disconnect the electrical connectors as necessary. INSTALLATION PROCEDURE 1. Connect the electrical connectors as necessary. 2. Install the switch to the instrument panel. 3. Connect the negative battery cable. Page 5874 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 7125 Abbreviations And Meanings - Part 18 Page 3448 Electronic Components Page 8135 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 3346 Engine Harness Rear (4.3L) Page 8980 Conversion English/Metric Part 2 Page 5116 Abbreviations And Meanings - Part 9 Page 7284 Abbreviations And Meanings - Part 10 Page 1813 8. Remove the crankshaft balancer key. 9. Clean the components with cleaning solvent. 10. Dry the components with compressed air. 11. Inspect the camshaft timing chain for binding or wear. 12. Inspect the camshaft sprocket and the crankshaft sprocket for: ^ Broken teeth (1) ^ Damaged teeth (2) ^ Chipped teeth (3) ^ Worn teeth ^ Uneven wear on the edge of the teeth ^ Worn valleys between the sprocket teeth Page 5484 Door Window Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Window The outer door weatherstrip is used in order to seal the inner and outer door panels and the window at the belt line. The outer door weatherstrip can be replaced. Do not remove the inner sealing strip since the strip is stapled to the trim panel. Removal Procedure 1. Open the window. 2. Remove outer door weather strip from the door. Installation Procedure 1. Position the weatherstrip and press it into place. 2. Close the window. Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The Malfunction Indicator Lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A Diagnostic Trouble Code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 8367 WA387E/57 - WA408G/44 A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 4952 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Locations Cruise Control Module (CCM) Page 2551 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 8369 WA519F/12 - WA519F/12 Page 9503 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 3847 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 6038 Page 642 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 5426 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 6474 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 5442 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 5655 C116 C2 (Engine Harness To Active Transfer Case Harness) Page 3022 Steps 4-7 Page 6297 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Latch Replacement - Lift Gate Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Latch Replacement - Lift Gate Removal Procedure 1. Remove the bellcrank. 2. Disconnect the electrical connectors, as needed. 3. Remove the screws that retain the liftgate latch to the liftgate. 4. Remove the liftgate latch from the liftgate. Installation Procedure 1. Install the liftgate latch to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the liftgate latch to the liftgate. Tighten the screws to 9 N.m (80 lb in). 3. Connect the electrical connectors, as needed. 4. Install the bellcrank. Page 1315 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 5334 C217 (Body Harness To IP Harness) Page 4176 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Page 7262 Equivalent - Decimal And Metric Part 2 Body Relay Block A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 2784 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1922 Spark Plug: Specifications Spark Plug Torque Used heads 15 Nm 11 lb. ft. New aluminum heads 20 Nm 15 lb. ft. New iron heads 30 Nm 22 lb. ft. Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Page 2706 Abbreviations And Meanings - Part 26 Page 7124 Abbreviations And Meanings - Part 17 Page 4635 1. Lubricate the following parts with clean brake fluid. ^ The piston ^ The piston seal ^ The brake caliper bore. Important: Ensure that the piston seal is not twisted in the brake caliper bore groove. 2. Install the piston seal. 3. Install the boot on the piston. 4. Install the piston in the caliper bore. Page 8368 WA423G/79 - WA519F/12 Locations Endgate Harness Routing View Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 5546 Abbreviations And Meanings - Part 25 Page 7120 Abbreviations And Meanings - Part 13 Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Procedures Sunroof / Moonroof Weatherstrip: Procedures SUNROOF WINDOW WEATHERSTRIP REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the sunroof window. 2. Remove the sunroof window weatherstrip from the sunroof window by gently pulling the weatherstrip away at one point and continuing around the perimeter of the window. INSTALLATION PROCEDURE 1. Locate the seam on the weatherstrip. 2. Place the seam at the center of the rear edge of the sunroof window. 3. Firmly press the weatherstrip into place. Ensure that the weatherstrip is seated properly around the entire perimeter of the window. 4. Install the sunroof window. Page 3559 3.2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 4.2. Turn the ignition to the ON position and depress the brake pedal to move the shift lever out of the park position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the steering column trim covers. 6. Enable the SIR system. Page 9620 Abbreviations And Meanings - Part 1 Page 6008 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 942 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the number 1 mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove the distributor and reinstall the distributor. 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the distributor clamp bolt to 25 N.m (18 lb ft). Page 9972 Wiper Arm: Service and Repair Wiper Park Replacement - Rear WIPER PARK REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the interior trim panel. 2. Remove two screws and the wiper arm park ramp from the vehicle. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper arm park ramp under the wiper arm and onto the vehicle with two screws. Tighten Tighten two screws to 9 N.m (80 lb in). 2. Install the interior trim panel. Power Steering Cooler Pipe/Hose Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Power Steering Cooler Pipe/Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the air cleaner assembly. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering cooler hose from the power steering pump. 4. Disconnect the power steering cooler hose from the power steering cooler. 5. Remove the power steering cooler hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Specifications Parking Brake Backing Plate: Specifications Rear Park Brake Backing Plate Mounting Bolts 100 ft. lbs. Page 6694 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 2497 Body Control Module (BCM) C1 Part 2 Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. OnStar(R) - Incorrect GPS Position Reported During Call Cellular Phone: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 9722 Abbreviations And Meanings - Part 12 Page 5721 C116 C1 (Active Transfer Case Harness To Engine Harness) Page 2600 Engine Control Module: Description and Operation Vehicle/Powertrain Control Module & the BCM VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(tm) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 1677 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -18° C (0° F) ..................................................................................................................................................... 5W-30 synthetic (preferred) , 0W-30 Page 2322 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 7657 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 5360 C430 (Chassis Harness To License Lamp Harness) (Export) Page 5545 Abbreviations And Meanings - Part 24 Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 8762 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. 2. Install the electrical connector to the switch. 3. Install the trim panel to the seat with 3 screws. 4. Install the seat to the vehicle. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the seat from the vehicle. Page 7917 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 5023 Abbreviations And Meanings - Part 12 Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. - After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 7093 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 818 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 7151 Driver/Vehicle Information Display: Service and Repair Driver Information Center Replacement (Without Sunroof) DRIVER INFORMATION CENTER REPLACEMENT (WITHOUT SUNROOF) REMOVAL PROCEDURE 1. Remove the screw at the front of the console that retains the console to the roof. 2. Pull downward at the rear of the console in order to remove the console from the roof. 3. Disconnect the electrical connections as needed. INSTALLATION PROCEDURE 1. Connect the electrical connections as needed. 2. Insert the mounting tabs into the roof panel and push upward on the rear of the console in order to install the console to the roof. 3. Install the screw at the front of the console that retains the console to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 1.9 N.m (17 lb in). Page 8667 Equivalent - Decimal And Metric Part 1 Locations Steering Wheel Control Switches Page 5169 Fuse Block - I/P Part 5 Fuse Block - Underhood Connector C1 Page 3428 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 7126 Abbreviations And Meanings - Part 19 Page 5186 Fuse Block - Underhood Connector C4 Part 2 Page 5651 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 2 Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Description and Operation Brake Warning Indicator: Description and Operation Brake Warning System Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: ^ The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The EBCM detects an ABS malfunction which disables dynamic rear proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. ^ The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Page 5211 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 5061 Page 9409 Abbreviations And Meanings - Part 22 Distributor Ignition (DI) System Description Engine Control Module: Description and Operation Distributor Ignition (DI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: The Throttle Position (TP) sensor - The Engine Coolant Temperature (ECT) sensor - The Mass Airflow (MAF) sensor - The Intake Air Temperature (IAT) sensor - The Vehicle Speed Sensor (VSS) - The transmission gear position or range information sensors - The engine Knock Sensors (KS) Latch Replacement - Rear Door Rear Door Latch: Service and Repair Latch Replacement - Rear Door Latch Replacement - Rear Door Removal Procedure 1. Raise the window to the closed position. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the inside door lock rod (1) from the latch assembly. 5. Remove the inside door handle rod from the latch assembly. 6. Remove the outside door handle rod from the latch assembly. 7. Disconnect the power actuator wiring connector, of equipped. 8. Remove the fasteners that retain the latch assembly to the door. 9. Remove the latch assembly from the door. 10. Remove the lock actuator from the latch. Installation Procedure 1. Install the lock actuator to the latch. 2. Install the latch assembly to the door. Page 3060 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 8964 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 4721 4. Install the rear brake shoes. 5. Install the park brake cable to the equalizer. 6. Install the park brake cable in the park brake cable connector. 7. Install the rear brake drums. Page 2420 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover wingnuts. 2. Remove the air cleaner cover. 3. Remove the air cleaner element. 4. Clear out any debris in the air cleaner housing. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner housing. 2. Install the air cleaner cover. Page 6514 Abbreviations And Meanings - Part 15 Page 6622 A/C Coupler O-ring: Service and Repair Compressor Sealing Washers COMPRESSOR SEALING WASHERS REPLACEMENT IMPORTANT:If you use the correct washers, there should be a space of 1.2 mm (0.047 in) between the suction/discharge hose block and the compressor rear head. 1. Clean all of the sealing surfaces with a lint-free rag in order to prevent dirt or foreign material from getting into the following sealing surface components: The washers - The hose block - The compressor ports 2. Install the sealing washer onto the pilots of the suction/discharge fitting. Ensure that the washers are seated against the surface of the block fitting. 3. Install the hose block to the compressor. Ensure that the sealing washers are seated within the compressor's machined surfaces. 4. Hold the block in place and tighten the attachment bolt by hand. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the bolt to..........33 N.m (24 lb ft). Page 8058 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (2 Door Utility) Frame Cushion or Insulator Replacement (2 Door Utility) Removal Procedure Properly support the frame when you change the frame cushions. If only one cushion is changed, lower the entire side on which the cushion in placed in order to provide clearance for the cushion. 1. Raise the vehicle slightly on a hoist. Refer to Vehicle Lifting. 2. Place jack stands under the body on the side of the vehicle that the cushions will be placed. 3. Remove the frame cushion bolts. 4. Remove the retainer. 5. Remove the lower cushion. 6. Lower the hoist enough in order to leave the body supported by the jack stands. 7. Remove the upper cushion. 8. Remove the shims, if equipped. Installation Procedure 1. Install the shims, if equipped. 2. Install the upper cushion. Page 5501 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 4113 2. Secure the master cylinder rod to the clutch pedal. Page 2032 Fan Shroud: Service and Repair Fan Shroud Replacement Removal Procedure 1. If equipped with the 2.2L, remove the air intake duct assembly: 1.1. Loosen the air intake duct clamps. 1.2. Remove the air intake duct push pins. 1.3. Remove the air intake duct assembly (1) from the fan shroud (3). 2. Remove the upper fan shroud bolts. 3. Remove the coolant recovery reservoir hose from the lower fan shroud. Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in. 1.52 mm Page 147 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 3729 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Page 4066 Page 1827 For vehicles repaired under warranty, use the table. Disclaimer Page 1482 Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Remove the timing chain and the camshaft sprocket. 2. Remove the valve lifters. 3. Remove the balance shaft drive gear. 4. Remove the camshaft retainer bolts and retainer. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. Page 6211 5. Remove the rear tie rod. Installation Procedure 1. Position the rear tie rod in the frame bracket. 2. Loosely install the following parts to the axle bracket: ^ The bolt ^ The washers ^ The nut Diagrams Ignition Coil Page 9558 2. Ensure that the rear window is at room temperature. 3. Inspect the grid line area that you will repair. Verify that the area is dry and free from contaminates. 4. Dampen a cloth with isopropyl alcohol. Use the damp cloth in order to wipe the grid line area clean. INSTALLATION PROCEDURE 1. Use a grease pencil in order to mark the grid line break (2) on the outside of the rear window with a grease pencil. IMPORTANT: Ensure that the grid line repair material is not beyond the expiration date. - Repair decal or tape must be used in order to control the width of the repair area. - If the repair decal is used, verify that the die-cut metering slot is the same width as the grid line. - Thoroughly stir the grid line repair material until a uniform color appears. - Verify that there are no air bubbles in the grid line repair material in the repair area. 1. Using GM P/N 12346001 (Canadian P/N 10951643) or equivalent to repair the grid lines. Apply the grid line repair (2) decal or 2 strips of the tape above and below the repair area. 2. Use the brush (3) in order to spread the grid line repair material (1). Ensure that the repair material covers all of the areas of the cut out. 3. Without disturbing the grid line repair material, carefully remove the decal or tape (2). NOTE: The grid line repair material must be cured with heat. To avoid heat damage to the interior trim, protect the trim near the repair area where heat is to be applied. 4. Use a heat gun in order to repair the grid line: Page 8382 WA812K/88 - WA813K/89 Page 4450 Front Frame Grounds Page 2057 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 5491 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 2048 7. Place the heater inlet hose in the retaining clip above the right side valve cover. 8. Close the retaining clip. Ensure that the clip locks. 9. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 9718 Abbreviations And Meanings - Part 8 Locations Steering Column Components Locations Left Hand Side Of Instrument Panel Page 5105 English Prevailing Torque Fastener Minimum Torque Development Part 1 Front Suspension Stabilizer Link: Specifications Stabilizer Shaft Link to Lower Control Arm Nut (RWD) 13 ft. lbs. Page 7627 Page 6450 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 2867 Crankshaft Position (CKP) Sensor Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Open the rear side door window. 2. Remove the rear side door window weatherstrip. Start the at butt joint and pull the weatherstrip from the window opening. Installation Procedure 1. Install the rear side door weatherstrip. 2. Locate the butt joint at the bottom center of the window opening and set the weatherstrip around the window opening. Page 3478 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 4584 11. Remove the park brake strut and the strut spring. 12. Remove the adjusting screw assembly and the adjusting screw spring from the brake shoes. 13. Inspect all remaining parts for discoloration due to heat or stress. Replace parts as needed. Installation Procedure 1. Lubricate the brake shoe backing plate, the adjusting screw threads, socket and socket face with a thin coat of high temperature silicone lubricant. Important: Do not interchange the right and left adjusting screws. Page 693 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Specifications Power Steering Fluid Cooler: Specifications Power Steering Cooler Retaining Bolts 7 ft. lbs. Page 2134 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry, any door opened, the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch, door jamb switch - Passenger door latch, door jamb switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(tm) data from the Passlock(tm) sensor. If the Passlock(tm) data is correct, the BCM will pass theft. The BCM will then transmit the code password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(tm) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(tm) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 2864 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 2770 Body Control Module (BCM) C1 Part 3 Sunroof Opening Position Switch Replacement Sunroof / Moonroof Switch: Service and Repair Sunroof Opening Position Switch Replacement SUNROOF OPENING POSITION SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Move the sunroof to the closed position. IMPORTANT: Remove the headliner. - The sunroof open position (SOP) switch is aligned to the drive cables. The SOP switch comes from the factory set to the sunroof glass panel CLOSED position. A position lock pin has been installed by the factory on the top of the SOP switch. This pin must remain until after the installation of the sunroof actuator and of the SOP switch. This lock pin locks the drive gears in place and must be removed before the complete sunroof module is installed to the vehicle. - If the SOP switch is removed for inspection, the sunroof must be in the CLOSED position. A position lock pin must be inserted. If a position lock pin is not available, place 2 wires, such as the ends of a paper clip, in the holes. 1. Remove the sunroof window. 2. Remove the sunroof control module. 3. If you reuse the SOP switch, insert the position lock pin (1) in order to lock the SOP switch in the closed position. 4. Remove the sunroof motor/actuator. 5. Disconnect the electrical connector from the SOP switch (3). 6. Remove the screw (2) which secures the SOP switch to the sunroof module. 7. Hold down on both of the drive cables. Lift up on the SOP switch in order to remove the switch from the sunroof module. INSTALLATION PROCEDURE 1. Use a flat-bladed tool if you adjust the cable mechanism and/or the cam mechanism in order to align the cable and/or the cam timing holes. IMPORTANT: The cable mechanisms and/or the cam mechanisms, on both sides of the glass, contain a set of timing holes. These holes are aligned in the CLOSED position of the sunroof glass panel . These holes are located on the side opposite the rear screw hole, which is used in order to mount the sunroof glass panel. When installing a new sunroof open position (SOP) switch, set the sunroof glass panel to the CLOSED position. When the timing holes are aligned, insert a pin with diameter 0.0317 mm (1/8 in) or a drill bit (1) into each set of the timing holes. Use tape in order to hold each pin in place. Page 6068 Conversion English/Metric Part 1 Page 2326 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Page 8535 Memory Seat Module - Driver C1 Part 2 Page 9258 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille. 2. Lift the temperature sensor upward in order to remove the temperature sensor. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the temperature sensor by sliding the temperature sensor downward. 3. Install the radiator grille. Page 3833 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 3265 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 5529 Abbreviations And Meanings - Part 8 Page 3610 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Page 246 Power Mirror Switch: Service and Repair Power Folding Outside Mirror Switch POWER FOLDING OUTSIDE MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the folding outside mirror switch by carefully using a flat-bladed tool in order to pry up on the leading edge. 3. Remove the accessory switch panel from the armrest. Use a flat-bladed tool in order to carefully pry the cover up at the front leading edge leaving the electrical connections connected. 4. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Install the power accessory switch mounting panel to the armrest. Ensure that the retainers lock into place. 3. Install the power folding mirror switch to the door trim panel. Ensure that the retainers lock into place. 4. Connect the battery negative cable. Page 8963 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 2133 Body Control Module (BCM) C3 Part 2 Page 3348 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 4184 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission. 2. Remove the clutch assembly, if equipped. 3. Remove the engine flywheel bolts. 4. Remove the engine flywheel (automatic transmission) (1), if applicable. 5. Remove the engine flywheel (manual transmission) (2), if applicable. Important: If replacing the engine flywheel (manual transmission), then NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel. 6. Note the position of any flywheel weights for assembly (if applicable). 7. Clean and inspect all parts. Installation Procedure Important: If replacing the engine flywheel (manual transmission), note the position and length of the original flywheel weights (if applicable). Flywheel weights of the same length must be installed into the new engine flywheel in the same location as the old flywheel weights were in the old engine flywheel. Page 4692 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure 1. Remove the master cylinder from the vehicle. 2. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 3. Carefully remove the brake master cylinder reservoir retaining pins. 4. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 5. Remove the seals from the master cylinder. Installation Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11 GM P/N 12377967, Canadian P/N 992667 or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 3067 Disclaimer Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 6530 Registered And Non-Registered Trademarks - Part 4 Page 2218 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 8888 Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Upper Sealing Strip Replacement - Rear Door Upper Removal Procedure Pull the weatherstrip from the door frame. Installation Procedure Push the weatherstrip molding over the door frame. Page 3236 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 5075 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 2746 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Disconnect the MAP sensor harness connector. 3. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor grommet. 5. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Page 594 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Page 5768 C403 (Body Harness To LH Tail Lamp Harness) (Domestic) Page 9573 Page 5079 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Locations Neutral Safety Switch: Locations Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 9379 Conversion English/Metric Part 2 Page 9507 Abbreviations And Meanings - Part 3 Page 792 Abbreviations And Meanings - Part 1 Bezel Replacement Front Door Panel: Service and Repair Bezel Replacement Handle Bezel Replacement - Inside Handle Bezel Replacement - Inside Removal Procedure 1. Remove the screw that retains the front inside door handle bezel to the door trim panel. 2. Remove the screw that retains the rear inside door handle bezel to the door trim panel. 3. Remove the inside door handle bezel from the door trim panel by sliding rearward. Installation Procedure 1. Route the inside door handle and the lock rod through the appropriate openings in the bezel. 2. Align the lock rod to the door lock knob. 3. Position the bezel and snap the bezel into place. 4. Install the rear inside door handle bezel to the door trim panel. 5. Install the front inside door bezel to the door trim panel. Page 9247 Service and Repair Thermostat: Service and Repair Thermostat Replacement Removal Procedure 1. Partially drain the cooling system. 2. Remove the air cleaner outlet duct. 3. Remove the throttle body bracket nuts and reposition the bracket. 4. Remove the water outlet housing mounting bolts. 5. Remove the water outlet housing from the lower intake manifold and set aside. 6. Remove the gasket or O-ring. Page 849 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 4165 When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations Page 5493 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 3585 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 4902 Abbreviations And Meanings - Part 2 Page 9694 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 5663 C203 (Body Harness To IP Harness) Part 4 Page 6591 1. Install the shaft key (4) into the hub key groove. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 2. Clean the following components: - The clutch plate - The clutch rotor (2) 3. Align the shaft key (4) with the shaft keyway (3). 4. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 5. Remove the forcing tip on the J 33013-B. 6. Reverse the body direction on the center screw. 7. Install the J 33013-B with the bearing. 8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 9. Hold the center screw with a wrench. 10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 11. Tighten the body several turns. 12. Remove the installer. Ensure that the shaft key remains in place in the keyway. 13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.20-0.30 in). 14. Remove the J 33013-B. 15. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub. 16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. Page 5178 Fuse Block - Underhood Connector C2 Part 1 Page 4946 Clutch Switch: Service and Repair Clutch Start Switch Replacement Removal Procedure 1. Remove the plastic retainer tabs from the clutch start switch. 2. Remove the clutch start switch from the push rod. 3. Remove the connector from the switch. Installation Procedure 1. Install the connector to the clutch start switch switch. 2. Install the clutch start switch to the pushrod with the plastic tabs. 3. Install the push rod to the clutch pedal. Page 9785 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 459 Engine, LR Page 6524 Abbreviations And Meanings - Part 25 Page 4917 Abbreviations And Meanings - Part 17 Page 6522 Abbreviations And Meanings - Part 23 Page 7268 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 7700 Registered And Non-Registered Trademarks - Part 1 Page 9376 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS NV 1500 Shift Boot: Service and Repair NV 1500 Control Lever and/or Boot Replacement Removal Procedure 1. If equipped remove the 3 console nuts and the console. 2. Remove the shift lever from the shift tower. Do not remove the shift lever adjusting nut. 3. Pull back the carpet to access the screws. 4. Remove the screws securing the boot to the panel. Installation Procedure 1. Install the boot over the shift tower. A/T - Intermittent Downshift/Slip/Cycling Diagnosis Fan Clutch: Technical Service Bulletins A/T - Intermittent Downshift/Slip/Cycling Diagnosis File In Section: 07 Transmission/Transaxle Bulletin No.: 99-07-30-016B Date: October, 2002 INFORMATION Subject: Diagnostic Information For Intermittent Transmission Downshift, Slip, Busy/cycling TCC or Noisy Cooling Fan Models: 1999-2000 Cadillac Escalade 2002-2003 Cadillac Escalade, Escalade EXT 1988-2003 Chevrolet Astro, Blazer, S-10, Silverado, Suburban 1989-2003 Chevrolet/Geo Tracker 1995-2003 Chevrolet Tahoe 1996-2003 Chevrolet Express 1988-1994 GMC S-15 1988-1999 GMC Suburban 1988-2003 GMC Safari, Sierra 1995-2003 GMC Sonoma, Yukon, Yukon XL 1996-2003 GMC Savana 1999-2001 GMC Envoy 1991-2001 Oldsmobile Bravada 2003 HUMMER H2 with Air Conditioning This bulletin is being revised to change the Model information and text. Please discard Corporate Bulletin Number 99-07-30-016A (Section 07 - Transmission/Transaxle) Some customers may comment that at times the transmission seems to slip, or that there is a loud roar from the engine with slow acceleration. This condition is most noticeable after the vehicle has sat idle for 12 or more hours, or on hot days when the A/C is on and the vehicle moves slowly with traffic. Typical comments from customers may include the following conditions: ^ Intermittent slipping ^ Intermittent downshift followed by an upshift, both with no apparent reason ^ Busyness or cycling of the TCC (torque converter clutch) at steady throttle conditions and on a level roadway ^ Noisy cooling fan The type of concern described above requires further definition. The customer should be asked the following questions: ^ Is the situation more pronounced with higher vehicle loads such as when pulling a trailer? ^ Do warmer ambient temperatures make the situation more pronounced? ^ When the condition occurred, did you have the A/C on, and were you driving in stop and go city traffic? ^ Does the condition exhibit itself on the first start-up after sitting more than eight hours? If the customer indicates that these conditions apply, and your observation confirms that the vehicle is operating properly, provide the customer with the vehicle operating description included at the end of this bulletin. Further action may not be necessary. A service procedure follows if further definition is required. Diagnostic Aids Cooling fan operation or the resulting sound varies. The cooling fan clutch may be described as a continuously variable clutch. If the vehicle engine is running, the fan blade is always turning unless the fan clutch is non-functional. The speed of the fan in relation to engine speed is temperature dependent. Page 5567 Application Table Part 3 Page 2061 9. Install the coolant recovery reservoir hose to the radiator. 10. Reposition the coolant recovery reservoir hose clamp to the radiator. 11. Fill the cooling system. Page 7249 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8122 Pull up on the lower edges of the cup holder in order to release the retaining clips and remove the cup holder from the vehicle. INSTALLATION PROCEDURE Install the front floor cup holder to the vehicle. Front Floor (Full Length (Auto Trans)) Console Replacement - Front Floor (Full Length (Auto Trans)) Removal Procedure 1. Remove the shift handle retaining clip at the front of the handle. 2. Remove the shift handle from the shift lever. Page 4561 2. Install the brake rotor. 3. Install the brake caliper mount. 4. Install the brake pads. Page 5798 Splice Pack SP204 Part 2 Page 6485 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Service and Repair Windshield Washer Spray Nozzle: Service and Repair WASHER NOZZLE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Raise and support the hood. 2. Disconnect the washer hose from the nozzle. 3. Compress tabs on the bottom of the nozzle to remove. INSTALLATION PROCEDURE 1. Install the nozzle to the hood by pressing into place. 2. Install the washer hose to the nozzle. Page 5714 C104 (Chassis Harness To Engine Harness) Sunroof Opening Position Switch Replacement Sunroof / Moonroof Switch: Service and Repair Sunroof Opening Position Switch Replacement SUNROOF OPENING POSITION SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Move the sunroof to the closed position. IMPORTANT: Remove the headliner. - The sunroof open position (SOP) switch is aligned to the drive cables. The SOP switch comes from the factory set to the sunroof glass panel CLOSED position. A position lock pin has been installed by the factory on the top of the SOP switch. This pin must remain until after the installation of the sunroof actuator and of the SOP switch. This lock pin locks the drive gears in place and must be removed before the complete sunroof module is installed to the vehicle. - If the SOP switch is removed for inspection, the sunroof must be in the CLOSED position. A position lock pin must be inserted. If a position lock pin is not available, place 2 wires, such as the ends of a paper clip, in the holes. 1. Remove the sunroof window. 2. Remove the sunroof control module. 3. If you reuse the SOP switch, insert the position lock pin (1) in order to lock the SOP switch in the closed position. 4. Remove the sunroof motor/actuator. 5. Disconnect the electrical connector from the SOP switch (3). 6. Remove the screw (2) which secures the SOP switch to the sunroof module. 7. Hold down on both of the drive cables. Lift up on the SOP switch in order to remove the switch from the sunroof module. INSTALLATION PROCEDURE 1. Use a flat-bladed tool if you adjust the cable mechanism and/or the cam mechanism in order to align the cable and/or the cam timing holes. IMPORTANT: The cable mechanisms and/or the cam mechanisms, on both sides of the glass, contain a set of timing holes. These holes are aligned in the CLOSED position of the sunroof glass panel . These holes are located on the side opposite the rear screw hole, which is used in order to mount the sunroof glass panel. When installing a new sunroof open position (SOP) switch, set the sunroof glass panel to the CLOSED position. When the timing holes are aligned, insert a pin with diameter 0.0317 mm (1/8 in) or a drill bit (1) into each set of the timing holes. Use tape in order to hold each pin in place. Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - GARAGE DOOR OPENER Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure to use when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Garage Door Opener in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 3586 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 9833 Abbreviations And Meanings - Part 19 Page 9006 Abbreviations And Meanings - Part 18 Page 6082 Abbreviations And Meanings - Part 5 Page 4539 WARRANTY INFORMATION Page 9554 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 5. Once the open (2) is located, repair the grid line. Page 4689 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Page 8868 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door (Drip Channel) Weatherstrip Replacement - Front Door (Drip Channel) Removal Procedure 1. Open the door. 2. Remove the weatherstrip drip channel (3). Installation Procedure Important: Apply the drip channel in an environment free of dust or dirt that could come in contact with the sticky backing (2) and prevent proper adhesion. 1. Clean the area where the drip channel is to be mounted. Use a general purpose adhesive remover. 2. Clean the affected body area with wax and grease remover, and wipe with isopropyl alcohol. 3. Dry the area thoroughly. 4. Ensure the body area is at a temperature range of 21-41°C (80-105°F). 5. Ensure that the drip channel is at a temperature range of 21-41°C (80-105°F). 6. Install end of drip channel begining at the upper rear corner (4) of front side door opening frame, towards the windshield reveal molding flange (1) removing the tape backing as seal is applied. 7. When the drip channel is in position use a roller to firmly attach the tape to the entire contact surface. Page 5320 C203 (Body Harness To IP Harness) Part 8 Page 8459 1. Install the sunroof switch to the sunroof console with 6 screws. 2. Connect the electrical connector to the driver information display module. 3. Install the DIC. Page 8669 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 3553 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Locations Ignition Coil, Ignition Control Module (ICM), Manifold Absolute Pressure (MAP) Sensor, Throttle Body, And EVAP Canister Purge Solenoid Page 4185 1. Note the position of the flywheel weights and install the NEW flywheel weights as required. A properly installed flywheel weight will be flush or slightly below flush with the face of the engine flywheel. 2. Install the engine flywheel (1 or 2) to the crankshaft. Align the engine flywheel locator hole to the flywheel locator pin. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine flywheel bolts. Tighten the engine flywheel bolts in sequence to 100 Nm (74 ft. lbs.). 4. Install the clutch assembly, if equipped. 5. Install the transmission. Page 8137 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 6480 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV1500 ................................................................................................................ ............................................................................................. 2.7L (2.9 Qt) NV3500 ............................ .............................................................................................................................................................. ................... 2.0L (2.2 Qt) Service and Repair Camshaft Gear/Sprocket: Service and Repair Timing Chain and Sprockets Replacement ^ Tools Required J 5825-A Crankshaft Gear Remover - J 5590 Crankshaft Gear Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both Sprockets line up. 4.2. The number four cylinder is at Top Dead Center (TDC) of the compression stroke. Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Page 251 Seat Rear Vertical Position Sensor - Driver (w/ Memory) Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT INFLATOR MODULE DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. - Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a collision or deployment of the air bag(s) for conditions less severe than intended. - The steering column -Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - The I/P knee bolsters and mounting points -Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - The I/P brackets, braces, etc.- Inspect for bending, twisting, buckling, or any other type of damage. - The seat belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - The I/P cross car beam - Inspect for bending, twisting, buckling, or any other type of damage. - The I/P mounting points and brackets - Inspect for bending, twisting, buckling, or any other type of damage. - The seats and seat mounting points - Inspect for bending, twisting, buckling, or any other type of damage. ACCIDENT WITH FRONTAL AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving air bag deployment, replace the following components. Inflatable restraint I/P module - Inflatable restraint steering wheel module - Inflatable restraint steering wheel module coil - Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint front end discriminating sensors Perform additional inspections on the following components. Steering wheel module coil and the coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. - Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, and inflatable restraint front end discriminating sensor - Inspect for any damage and repair or replace each component as needed. SENSOR REPLACEMENT GUIDELINES The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 9146 Abbreviations And Meanings - Part 24 Service and Repair Transmission Mount: Service and Repair Transmission Mount Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge 0.80 kg 1.75 lb. Page 7630 Page 5991 3. Lubricate the O-ring seal (3) with power steering fluid. 4. Install the O-ring seal (3). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the connector and fitting assembly (3) to the pump housing (1). Tighten the connector and fitting assembly (3) to 75 Nm (55 ft. lbs.). Off Vehicle (P Series) Power Steering Pump Flow Control Valve Replacement - Off Vehicle (P Series) Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the connector and fitting assembly (4). 3. Remove the O-ring seal (3). Page 7646 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 2564 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening Removal Procedure 1. Open the endgate or the liftgate. 2. Remove the weatherstrip molding from the pinch-weld flange. 3. Firmly grip the weatherstrip. 4. Pull the weatherstrip out and away from the vehicle. Installation Procedure 1. Push the weatherstrip onto the pinch weld flange, beginning from the top corner of the endgate opening. 2. Completely seat the weatherstrip around the endgate or the liftgate opening. Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 9727 Abbreviations And Meanings - Part 17 Page 1617 engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 8302 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 1347 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 9980 3. Pull upward until the locking tab of the pivot engages the slot in the hook. 4. Carefully lower the wiper arm and blade onto the windshield. Page 2667 Equivalent - Decimal And Metric Part 1 Page 9678 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1791 Engine Oil Pressure (EOP) Sensor Page 6492 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 3829 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 9519 Abbreviations And Meanings - Part 15 Page 8406 Memory Seat Module - Driver C1 Part 2 Page 5739 C209 (Dome Harness To Body Harness) Part 1 Locations Seat Switches Page 1916 Tighten the distributor clamp bolt to 25 N.m (18 lb ft). 8. Install the distributor cap. 9. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. 13. Repeat installation procedure 2 if the malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the MIL is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. EVAP Hoses/Pipes Replacement - Engine Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Engine REMOVAL PROCEDURE 1. Disconnect the evaporative emission (EVAP) pipe from the EVAP canister purge valve. 2. Disconnect the EVAP (2) pipe from the EVAP front chassis pipe (1). INSTALLATION PROCEDURE 1. Connect the EVAP pipe (2) to the EVAP front chassis pipe (1). Locations Air Door Actuator / Motor: Locations Instrument Panel, RF Page 9142 Abbreviations And Meanings - Part 20 Page 5046 6. Disconnect the wires from the solenoid. 7. Remove the starter from the vehicle. Note the location of the shims, if equipped. INSTALLATION PROCEDURE 1. Connect the wires to the solenoid. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the battery positive cable nut to 9 N.m (80 lb in). - Tighten the engine wiring harness to starter nut to 1.9 N.m (17 lb in). Page 6721 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner outlet duct. 3. Disconnect the A/C high pressure switch electrical connector (2). 4. Remove the A/C high pressure switch connector retaining ring. 5. Remove the A/C high pressure switch from the A/C compressor. INSTALLATION PROCEDURE 1. Install the A/C high pressure switch to the A/C compressor. 2. Install the A/C high pressure switch connector retaining ring. 3. Connect the A/C high pressure switch electrical connector (2). 4. Install the air cleaner outlet duct. 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings of the components using the J 39400-A. Page 3463 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 647 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 255 Seat Harness Routing (8-Way w/o Memory) Page 2040 For vehicles repaired under warranty, use the table. Disclaimer Page 6102 Abbreviations And Meanings - Part 25 Page 4750 11. Install the brake caliper and mounting bracket. 12. Install the tire and wheel. 13. Lower the vehicle. Refer to Vehicle Lifting. Heater Hose - Inlet Heater Hose: Service and Repair Heater Hose - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Release the heater inlet hose clamp using the J 38185 at the heater core. 3. Remove the heater inlet hose from the heater core. 4. Release the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Remove the heater inlet hose from the intake manifold fitting. A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Page 5775 C432 (Body Harness To Defogger Grid Harness) Locations Seat Harness Routing (8-Way w/o Memory) Diagrams Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearing Cap Bolt - Preferred Method First Pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 73 degrees Crankshaft Bearing Cap Bolt - Optional Strategy ................................................................................................................................... 105 Nm (77 ft. lbs.) Crankshaft Main Bearing Bore Out-of-Round ................................................................................................................................... 0.050 mm (0.002 inch) Crankshaft Main Bearing Clearance #1 - Production ................................................................................................ 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Crankshaft Main Bearing Clearance #2, #3, and #4 - Production ......................................................................... 0.028 - 0.058 mm (0.0011 - 0.0023 inch) Crankshaft Main Bearing Clearance #1 - Service ................................................................................................. 0.0254 - 0.05 mm (0.0010 - 0.0020 inch) Crankshaft Main Bearing Clearance #2, #3, and #4 Service ............................................................................... 0.025 - 0.063 mm (0.0010 - 0.0025 inch) Page 6818 Impact Sensor: Service and Repair INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove off road skid plate, if equipped. 3. Remove the connector position assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 4. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. 5. Drill out the mounting rivets. 6. Remove the inflatable restraint front end discriminating sensor from the vehicle. Page 5485 Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft bracket mounting bolts. 3. Remove the stabilizer shaft bracket. 4. Lower the stabilizer shaft and remove the stabilizer shaft insulator. Installation Procedure 1. Install the stabilizer shaft insulator to the stabilizer shaft with the slits facing the front of the vehicle. 2. Install the stabilizer shaft bracket over the stabilizer shaft insulator. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft bracket mounting bolts. Tighten the stabilizer shaft bracket mounting bolts to 36 Nm (26 ft. lbs.). 4. Lower the vehicle. Page 3973 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 6033 Page 7757 Front Bumper Reinforcement: Service and Repair Brace Replacement - Front Bumper (Chevrolet) Brace Replacement - Front Bumper (Chevrolet) Removal Procedure 1. Remove the nut and the bolt that retain the brace to the impact bar. 2. Remove the 2 nuts and bolts that retain the brace to the frame. 3. Remove the brace from the vehicle. Installation Procedure 1. Install the brace to the vehicle. 2. Install the 2 nuts and bolts that retain the brace to the bumper frame. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nut and the bolt that retain the brace to the bumper impact bar. Tighten the front bumper brace bolts to 40 N.m (30 lb ft). Page 2737 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 6460 Page 4364 Park Neutral Position (PNP) Switch Page 3216 5. Disconnect the accelerator cable from the throttle body. 6. Remove the nuts retaining the accelerator cable routing bracket. 7. Position the bracket aside. 8. Remove the stud and nuts retaining the accelerator control cable bracket. 9. Position the bracket aside. 10. Disconnect the idle air control (IAC) valve harness connector. Page 937 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 9793 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 4994 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 7633 Page 9496 Conversion English/Metric Part 2 Page 5726 C201 (Steering Column Harness To Redundant Steering Wheel Control Harness) C203 - Body Harness to IP Harness Page 4556 5. Remove the retaining ring, 4 wheel drive vehicles only. 6. Remove the brake rotor, 4 wheel drive vehicles only. 7. Remove the brake rotor and wheel bearings, 2 wheel drive vehicles only. 8. Inspect the brake rotor. 9. Inspect the brake caliper. 10. Refinish the rotor if necessary. Installation Procedure Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. Page 2594 Powertrain Control Module (PCM) Connector C2 Part 3 Page 9160 Driver Information System Diagram 2 Page 9125 Abbreviations And Meanings - Part 3 Service and Repair Front Door Latch: Service and Repair Latch Replacement - Front Door Removal Procedure 1. Raise the window to the closed position. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the inside door lock rod (1) from the latch assembly. 5. Remove the inside door handle rod (2) from the latch assembly. 6. Remove the outside door lock rod (1) from the latch assembly. 7. Remove the outside door handle rod (2) from the latch assembly. 8. Disconnect the power actuator wiring connector, if equipped. 9. Remove the fasteners that retain the latch assembly to the door. 10. Remove the latch assembly from the door. 11. Remove the lock actuator from the latch. Installation Procedure 1. Install the lock actuator to the latch. 2. Install the latch assembly to the door. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the fasteners that retain the latch assembly to the door. Tighten the fasteners to 9 N.m (80 lb in). 4. Connect the power actuator wiring connector, if equipped. Page 2190 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 4937 3. Install the drive belt idler pulley. 4. Install the drive belt tensioner. 5. Install the engine wiring harness bracket to the generator mounting bracket. Tighten Tighten the engine wiring harness bracket bolt to 25 N.m (18 lb ft). 6. Install the generator. 7. Install the drive belt. 8. Install the engine cooling fan. 9. Connect the negative battery cable. Page 4965 Page 5222 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 6389 Disclaimer Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 3418 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 1178 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Page 9148 Abbreviations And Meanings - Part 26 Page 2857 Disclaimer Page 6451 Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 4580 Backing Plate: Service and Repair Brake Backing Plate Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the brake shoes. 5. Remove the wheel cylinder. 6. Remove the axle shaft. 7. Remove the backing plate bolts. 8. Remove the backing plate. Installation Procedure 1. Install the backing plate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate bolts. Tighten the bolts to 48 Nm (35 ft. lbs.). 3. Install the axle shaft. 4. Install the wheel cylinder. 5. Install the brake shoes. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Bleed the brake system. Page 8029 1. Install the center vent grille panel to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that secure the center vent grille panel to the cowl. Tighten the screws to 1.5 N.m (13 lb in). 3. Install the push-pin retainers securing the center vent grille panel to the cowl. 4. Install the right and the left vent grille end panels to the cowl. Tighten the screws to 1.5 N.m (13 lb in). 5. Install the screws securing the securing the right and the left vent grille ends to the cowl. 6. Install the windshield wiper arms. Page 7091 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 6223 The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Page 4880 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 7819 1. Install the lower door striker to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the lower door striker. Tighten the bolts to 10 N.m (89 lb in). Page 5689 C301 (Dome Harness To Overhead Console) (w/o GDO) Page 3606 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 7668 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5302 C106 (Forward Lamp Harness To Body Harness) Part 2 C106 (Forward Lamp Harness To Body Harness) (Export) Page 6200 Shock Absorber Disposal Shock Absorber Disposal Caution: ^ Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force, which may result in personal injury. ^ To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 2646 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 5531 Abbreviations And Meanings - Part 10 Page 9769 Page 4745 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Page 8452 Sunroof Switch Page 5758 C303 (Power Seat Harness, RH To Power Recliner Harness, RH) (w/ Power Seats, Non-Memory) Page 2656 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 8949 Page 2263 Engine, LR Page 1475 8. Remove the crankshaft balancer key. 9. Clean the components with cleaning solvent. 10. Dry the components with compressed air. 11. Inspect the camshaft timing chain for binding or wear. 12. Inspect the camshaft sprocket and the crankshaft sprocket for: ^ Broken teeth (1) ^ Damaged teeth (2) ^ Chipped teeth (3) ^ Worn teeth ^ Uneven wear on the edge of the teeth ^ Worn valleys between the sprocket teeth Page 9560 - The defogger terminal 14. Remove the excess flux with the solvent. IMPORTANT: Do not remove the holding force until the solder has solidified. 15. Connect the electrical connector. Bus Bar Lead Terminal Repair BUS BAR LEAD TERMINAL REPAIR 1. Clean the repair area by buffing with fine steel wool. This removes the oxide coating formed during the window manufacture. IMPORTANT: The rear defogger bus bar lead wire, the antenna, or the defogger terminal can be reattached by resoldering using a solder containing 3 percent silver and a rosin flux paste. 2. Install the paste-type rosin flux in small quantities to the rear defogger bus bar lead wire antenna or the defogger terminal repair area using a brush. 3. Coat the solder iron tip with the solder. - Use only enough heat to melt the solder. - Use only enough solder to ensure a complete repair. NOTE: Use only enough heat to melt the solder. Using excessive heat can damage the rear window defogger components or the rear window. 4. Install the solder to the feed bus bar or the ground bus bar. 5. Draw the soldering iron tip across the fluxed area, thinly coating the bus bar with solder. 6. Install a small amount of flux to the underside of the rear defogger bus bar lead wire antenna or the defogger terminal. 7. Align the spots with flux to the underside of the rear defogger bus bar lead wire, antenna, or defogger terminal. 8. Coat the tip of the soldering iron with solder. 9. Install the solder to the underside of the rear defogger bus bar lead wire antenna to the defogger terminal. 10. Draw the iron across the fluxed spot, thinly coating the spot of solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. - Use pliers in order to hold the rear defogger bus bar lead wire antenna or the defogger terminal. - Apply the heat to the top of the rear defogger bus bar lead wire antenna or the defogger terminal. This causes the solder spot to melt and fuse together. - Do not remove the holding force until the solder has solidified. - Wipe off the excess flux with solvent. 12. Install the electrical connector. Page 5017 Abbreviations And Meanings - Part 6 Page 9688 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 9575 Adjustments Trunk / Liftgate Latch: Adjustments Latch Adjustment - Rear Lift Window Panel Removal Procedure 1. Perform the following steps in order to inspect the window latch assembly for proper adjustment: 1. Hold the outside window handle. 2. Try to move the window in and out. If the latch is misaligned to the striker, a rattle condition will exist. 3. Inspect the window for a snug fit against the top and the sides of the body opening. 2. If the latch is misaligned and/or the window is not snug against the weatherstrip, adjust the latch using the following procedure. 3. Remove the endgate or the liftgate trim panel. 4. Remove the endgate cover. 5. Use a flat-bladed tool in order to carefully pry the window latch forward and backward. This will help to loosen the window latch nut. 6. Adjust the latch assembly location. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the latch assembly nut or nuts. Tighten the nuts to 10 N.m (89 lb in). Inspect the window panel for proper operation. 2. Install the endgate cover (if removed). 3. Install the endgate or the liftgate trim panel. Page 4285 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 9736 Abbreviations And Meanings - Part 26 Page 5377 Splice Pack SP200 Part 2 Page 8085 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 9452 Dome Lamp Harness W/O Driver Information Center (DIC) Electronic Components Electronic Components Page 5516 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 9821 Abbreviations And Meanings - Part 7 Page 2377 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 1894 For vehicles repaired under warranty, use the table. Disclaimer Page 6314 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 4907 Abbreviations And Meanings - Part 7 Page 945 4. Using a long screw driver, align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine. 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. - There may be a 6 cast into this pointer, indicating that the distributor is to be used on a 6 cylinder engine or an 8, indicating that the distributor is to be used on a 8 cylinder engine. - If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more. - If this is the case, repeat the procedure again in order to achieve proper alignment. 7. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Raise and support the hood. 2. Remove the bolt from the right and the left vent grille end panels. 3. Lift up on the right and the left vent grille end panels to release the retaining clips. 4. Remove the right and the left vent grille end panels. 5. Remove the screws that secure the center vent grille panel to the cowl. 6. Remove the push-pin retainers that secure the center vent grille panel to the cowl. 7. Remove the center vent grille panel from the cowl. Installation Procedure Page 4866 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 2286 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 9646 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 3347 Knock Sensor (KS) Page 2306 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 5636 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 2844 Disclaimer Page 449 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 1774 29. Install air cleaner outlet duct to throttle body. 30. Install air cleaner outlet duct to MAF sensor. Tighten the hose clamp to 4 Nm (32 inch lbs.). 31. Connect the IAT sensor harness connector. 32. Install the air cleaner outlet duct retaining wingnut. Tighten the wingnut to 2 Nm (18 inch lbs.). 33. Connect the breather tube to the air cleaner outlet duct. Page 9784 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 8855 11. Install the rear brace to the rear bumper bracket and step panel using the 2 screws. Tighten Tighten the rear brace screws to 9.0 N.m (6.6 lb ft). Page 2050 8. Remove the heater outlet hose from the retaining clip at the engine water outlet. 9. Open the outlet heater hose retaining clip above the right side valve cover. Use a flat bladed tool to open the clip from the bottom. 10. Remove the outlet heater hose from the vehicle. INSTALLATION PROCEDURE 1. Apply lubricant, GM P/N 9985662, to each end of the outlet heater hose. 2. Install the outlet heater hose to the vehicle. IMPORTANT:When installing new outlet heater hose, place the clamp on the hose before installing the hose to the vehicle. Page 5063 Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front .................................................................................................................................................... ..................................................................... 2.6 Pints Rear ................................................................ .......................................................................................................................................................... 4.0 Pints Page 2982 5. Remove the purge solenoid from the intake manifold. INSTALLATION PROCEDURE 1. Install the purge solenoid to the intake manifold. 2. Install the engine wiring harness bracket to the mounting stud. 3. Install the purge solenoid mounting nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 12 N.m (106 lb in). Page 148 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 5492 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 2188 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 8621 IMPORTANT: Do not damage the seat fabric when removing the velcro retaining cover. 7. Disconnect the electrical connections, as needed. 8. Remove the seat back release lever, if equipped. 9. Remove the manual lumbar support knob, if equipped. 10. Remove the power seat control switch, if equipped. 11. Remove the seat back from the seat bottom bolts. 12. Remove the seat belt buckle bolt. 13. Remove the seat belt buckle from the seat. 14. Remove the seat bottom cover. 15. Remove the seat bottom pad. INSTALLATION PROCEDURE 1. Install the seat bottom pad to the seat bottom. 2. Install the seat bottom cover over the pad. 3. Engage the hook and loop strips (1) that retain the seat pad (3) to the seat cover (2). 4. Install the seat belt buckle through the slot in the seat. Page 696 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 534 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Disconnect the MAP sensor harness connector. 3. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor grommet. 5. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Page 880 Steps 4-7 Page 8642 Page 4746 Disclaimer Page 3201 Mass Air Flow (MAF) Sensor Page 1591 8. Use the J 5892-D in order to compress the valve spring. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9. Apply steady pressure on the valve spring cap until the valve keys are accessible. Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use the J 38606 if the clearance does not permit use of the J 5892-D. 11. Install the valve stem O-ring seal. 12. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 13. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 14. Remove the J 5892-D or the J 38606. 14.1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 14.2. Tap the end of the valve stem with a plastic faced hammer in order to seat the valve stem keys, if necessary. Page 8204 6. Position the sunroof switch (4) to the motor/actuator trim cover (5). 7. Locate switch to cover in order to secure. 8. Position motor/actuator trim cover to the sunroof panel window garnish molding. 9. Install the motor/actuator trim cover screw (2). Tighten the screw to 1.5 N.m (13 lb in). 10. Install the motor/actuator service cover. Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Use the J 38778 in order to remove the windshield garnish molding from the windshield pillar. Pull the molding away from the pillar and then up. Installation Procedure Install the windshield molding to the windshield pillar. Align the retainer clips with the slots and press the molding into place. Trim Panel Replacement - Body Side (Crew Cab) Page 564 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Service and Repair Center Link: Service and Repair Relay Rod Replacement ^ Tools Required J 6627-A Tie Rod Puller - J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the inner tie rods ball stud nuts. Important: Use the proper tool in order to separate all ball joints. 3. Disconnect the inner tie rods ball studs from the relay rod using J 6627-A. 4. Remove the relay rod ball stud nut at the pitman arm. Locations Endgate Harness Routing View Page 3047 Disclaimer Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Remove the master cylinder rod from the clutch pedal. 2. Remove the clutch pedal from the support by depressing the side tabs. Installation Procedure 1. Position the clutch pedal into the support. Page 6119 Steering Wheel: Description and Operation STEERING WHEEL AND COLUMN The steering wheel and column are designed to absorb energy when driver contact is made with the steering wheel or inflated air bag. In a frontal collision the driver may contact the steering wheel directly or load the steering wheel and column through the inflated air bag. When the driver applies load to the air bag or steering wheel the column will compress downward absorbing some of the impact, helping to reduce bodily injuries to the driver. The steering wheel and column must be inspected for damage after a collision. Page 9661 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 4918 Abbreviations And Meanings - Part 18 Page 9458 Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolt/Stud First Pass ............................................................................................................................................. .................................................. 15 Nm (11 ft. lbs.) Final Pass ........................................................... ................................................................................................................................... 30 Nm (22 ft. lbs.) Exhaust Manifold Surface Flatness - Flange to Flange ................................................................................................................................................. 0.25 mm (0.010 inch) Surface Flatness - Individual Flange ................................................................................................................................................ 0.05 mm (0.002 inch) Page 4277 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Page 6453 Page 4515 1. Install the caliper bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear brake caliper bracket mounting bolts. Tighten the rear brake caliper bracket mounting bolts to 70 Nm (52 ft. lbs.). 3. Install the rear brake anti rattle retainers. 4. Install the rear brake pads. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Refer to Vehicle Lifting. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the brake master cylinder to the proper level. Page 5103 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 1746 Intake Manifold: Specifications Evaporative Emission (EVAP) Canister Purge Solenoid Valve Nut to Intake Manifold ...................................................................... 10 Nm (89 inch lbs.) Lower Intake Manifold Bolt First Pass in Sequence ........................................................................................................................ ................................................. 3 Nm (27 inch lbs.) Second Pass in Sequence ................................. ................................................................................................................................ 12 Nm (106 inch lbs.) Final Pass in Sequence ............................................................................................................... ........................................................... 15 Nm (11 ft. lbs.) Upper Intake Manifold Stud First Pass ............................................................................................................................................. ................................................ 5 Nm (44 inch lbs.) Final Pass ............................................................ ................................................................................................................................ 9 Nm (80 inch lbs.) Intake Manifold Surface Flatness .................................................................................................................................. ............................................. 0.10 mm (0.004 inch) Throttle body attaching studs .............................................................................................................. .................................................... 9 Nm (80 inch lbs.) Page 3321 Distributor: Service and Repair Distributor Inspection 1. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 1.1. Remove the cap. 1.2. Place 1 lead from the DMM on a cap terminal. 1.3. Use the other lead in order to probe all other terminals and the center carbon ball. 1.4. Move the base lead to the next terminal. Probe all other leads. 1.5. Continue this procedure until you test all the secondary terminals. 1.6. If there are any non-infinite readings, replace the cap. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 3. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 4. Inspect the shaft for shaft-to-bushing looseness: 4.1. Inspect the housing for cracks or damage. 4.2. Insert the shaft in the housing. 4.3. If the shaft wobbles, replace the housing assembly. Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Remove the body side stationary window (2-Door only). 2. Remove the molding from the quarter panel rear window (4-Door only). 3. Remove the pressure relief ventilation valve using a flat-bladed tool in order to release the retainers. Installation Procedure 1. Install the pressure relief ventilation valve assembly pressing into place until firmly seated. Page 7094 Equivalent - Decimal And Metric Part 1 Page 7680 Abbreviations And Meanings - Part 8 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8655 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Diagrams Passlock Sensor Page 6046 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Locations Clutch Switch: Locations Instrument Panel, LF Page 5345 C304 (Body Harness To LR Door Harness) (4-Door) Page 3059 Mass Air Flow (MAF) Sensor Page 814 Abbreviations And Meanings - Part 23 Page 6226 ^ Also, finger apply a small amount of grease inboard of each bearing cup in the rotor. ^ Pressure pack the bearings with a grease machine or hand pack the bearings. Make sure the grease is worked thoroughly into the rollers, the cone, and the cage. 1. Install the inner and outer races, if necessary. 2. Install the inner bearing to the rotor. 3. Apply an additional quantity of grease outboard of the inner bearing. 4. Install the seal. 4.1. Lubricate the seal lip. 4.2. Use a flat plate in order to press the seal down flush with the wheel hub. 4.3. Seat the outer wheel bearing and the cup. Important: Do not scuff the spindle threads. 5. Install the wheel and bearing to the spindle. 6. Install the outer bearing to the rotor. 7. Install the washer. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the spindle nut. Tighten the spindle nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. 9. Adjust the wheel bearings. 10. Install new cotter pin. Bend the pin ends against the nut flats. 11. Install the dust cap to rotor. 12. Install the brake caliper. 13. Install the tire and the wheel. 14. Lower the vehicle. Page 8972 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 8538 Memory Seat Module - Driver C3 Page 7928 Page 5192 Relay Block - Body Part 2 Page 6518 Abbreviations And Meanings - Part 19 Page 5069 Page 2654 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Specifications Brake Fluid: Specifications Fluid Type See Note use only Delco Supreme or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 185 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The Powertrain Control Module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The Ignition Control (IC) - The Knock Sensor (KS) system - The Evaporative Emissions (EVAP) system - The Secondary Air Injection (AIR) system (if equipped) - The Exhaust Gas Recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the Malfunction Indicator Lamp (MIL). When the PCM detects a malfunction, the PCM stores a Diagnostic Trouble Code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. Page 3820 Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Raise the vehicle. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 645 Engine Harness Rear (4.3L) Page 5098 Conversion English/Metric Part 1 Page 3871 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Service and Repair Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. - Tighten the backup lamp switch to 37 Nm (27 ft. lbs.). 2. Connect the backup lamp switch electrical connector. 3. Lower the vehicle. Page 6433 5. Install the right side driver knee bolster bracket (2) to the steering column bracket (1) and the intermediate bracket (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten - Tighten the knee bolster bracket mounting nuts (5) to 5.5 N.m (49 lb in). - Tighten the intermediate bracket mounting bolts (4) to 10 N.m (88 lb in). 1. Install the knee bolster. Page 9698 Equivalent - Decimal And Metric Part 2 Page 8911 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector. 4. Remove the 3 nuts that retain the cruise control module to the mounting bracket studs. 5. Remove the cruise control module from the mounting bracket. 6. Remove the 3 screws that retain the mounting bracket to the cowl panel. INSTALLATION PROCEDURE 1. Install the mounting bracket to the cowl panel with the 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cruise control module bracket screws to 4.5 N.m (40 lb in). 2. Install the cruise control module to the vehicle. 3. Install the 3 nuts that retain the cruise control module to the mounting bracket. Page 8748 Seat Adjuster Switch - Driver (w/ 6-Way) Part 2 Page 2951 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the throttle body. 2. Remove the mounting screws from the throttle position (TP) sensor. 3. Remove the TP sensor from the throttle body assembly. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result. INSTALLATION PROCEDURE 1. Place the TP sensor over the throttle shaft and align the TP mounting holes with their corresponding holes in the throttle body assembly. Page 1765 14. Remove the accelerator cable bracket from the throttle body and the intake manifold. 15. Remove the accelerator and cruise control cable bracket from the throttle body. Leave the accelerator and cruise control cables on the bracket. 16. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. Page 9187 Page 5311 C200 (IP Harness To Body Harness) Page 4920 Abbreviations And Meanings - Part 20 Page 7281 Abbreviations And Meanings - Part 7 Procedures Sunroof / Moonroof Weatherstrip: Procedures SUNROOF WINDOW WEATHERSTRIP REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the sunroof window. 2. Remove the sunroof window weatherstrip from the sunroof window by gently pulling the weatherstrip away at one point and continuing around the perimeter of the window. INSTALLATION PROCEDURE 1. Locate the seam on the weatherstrip. 2. Place the seam at the center of the rear edge of the sunroof window. 3. Firmly press the weatherstrip into place. Ensure that the weatherstrip is seated properly around the entire perimeter of the window. 4. Install the sunroof window. NV 1500 Transmission Speed Sensor: Service and Repair NV 1500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the vehicle speed sensor electrical connector. 3. Remove the vehicle speed sensor retaining bolt. 4. Remove the vehicle speed sensor. Installation Procedure 1. Install the new O-ring seal to the vehicle speed sensor. 2. Coat the new O-ring seal with a thin film of transmission fluid. 3. Install the vehicle speed sensor Notice: Refer to Fastener Notice in Service Precautions. 4. Install the vehicle speed sensor retaining bolt. ^ Tighten the vehicle speed sensor retaining bolt to 16 Nm (12 ft. lbs.). 5. Connect the vehicle speed sensor electrical connector. 6. Lower the vehicle. Page 558 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Heated Glass Element DIAGNOSTIC STARTING POINT - HEATED GLASS ELEMENT For the inside rearview mirror with the automatic day-night feature or the rear window defogger (w/o C68), begin the diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures For the rear window defogger, begin the diagnosis with the Diagnostic System Check - Defogger. The Diagnostic System Check will provide the following information: - The identification of the control module(s) which command the system - The ability of the control module(s) to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Defogger DIAGNOSTIC SYSTEM CHECK - DEFOGGER TEST DESCRIPTION Page 2273 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Replacement REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Disconnect the MAP sensor harness connector. 3. Remove the MAP sensor by pulling straight up with a slight rocking motion. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor grommet. 5. Discard the MAP sensor grommet. INSTALLATION PROCEDURE 1. Install the new MAP sensor grommet on the MAP sensor. Page 3429 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 6066 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 7380 Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 9152 Registered And Non-Registered Trademarks - Part 3 Page 4641 8. Remove the brake caliper guide pin bolts. 9. Remove the brake caliper assembly. Installation Procedure 1. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. Page 5251 C203 (Body Harness To IP Harness) Part 6 Page 8134 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. Page 9371 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 3297 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 1477 5. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole). 6. Install camshaft sprocket bolts. Tighten the camshaft sprocket bolts to 25 Nm (18 ft. lbs.). 7. Install the crankshaft position sensor reluctor ring. 7.1. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. 7.2. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft Page 3202 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 1224 Fuse Block - Underhood Connector C3 Part 3 Page 5743 C211 (Steering Column Harness To Body Harness) Part 1 Page 9777 Diagrams Power Seat Control Module: Diagrams Memory Seat Module - Driver C1 Part 1 Page 7369 Page 6041 Page 5035 Abbreviations And Meanings - Part 24 Service and Repair Sunroof / Moonroof Track: Service and Repair SUNROOF WINDOW TRACK ASSEMBLY REPLACEMENT WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. Remove the sunroof motor/actuator. 2. Remove the long gold assembly screw. 3. Remove the sunroof window. 4. Remove the screws (1) from the window track. 5. Remove the window track assembly from the upper frame assembly. INSTALLATION PROCEDURE 1. Install the window track assembly (left side) to the upper frame. Let the right side assembly hang. 2. Install the screws. 3. Lift the (right side) to the upper frame track. 4. Ensure the drive tubes are positioned into the front end of the window track. 5. Install the screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 4.0 N.m (35 lb in). Page 3686 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 6908 Impact Sensor: Diagrams Inflatable Restraint Front End Discriminating Sensor - Left Page 5314 C203 (Body Harness To IP Harness) Part 2 Page 2788 Powertrain Control Module (PCM) Connector C1 Part 2 Page 4775 Page 5616 Fuse Block: Application and ID Underhood Fuse Block Fuse Block - Underhood Details (Uplevel Utility) Application Table Part 1 Page 1693 3. Install the oil filter adapter bolts. Tighten the oil filter adapter bolts to 21 Nm (15 ft. lbs.). 4. Install the oil filter adapter pipe seals and pipes to the oil filter adapter. 5. Install the oil filter adapter pipe bolt. Tighten the oil filter adapter pipe bolt to 35 Nm (26 ft. lbs.). 6. Install the engine oil filter (except Four Wheel Drive vehicles). 7. Lower the vehicle. 8. Operate the engine and check for leaks. 9. Inspect the engine oil level and fill to the proper level. Page 5760 C305 (Body Harness To LR Door Harness) (4-Door) Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Light Switch Mounting Bolt 35 inch lbs. Page 3460 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 3157 7. Refill the fuel tank. 8. Tighten the fuel filler cap. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition. 10.4. Inspect for fuel leaks. Heater Hose - Inlet Heater Hose: Service and Repair Heater Hose - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Release the heater inlet hose clamp using the J 38185 at the heater core. 3. Remove the heater inlet hose from the heater core. 4. Release the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Remove the heater inlet hose from the intake manifold fitting. Page 936 14. Remove the round washer. 15. Remove the tang washer. 16. Remove the shim washer (1). 17. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the CMP sensor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. Insert the sensor into the housing. Page 2664 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 768 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch - Driver (Utility, Crew Cab W/ RKE) Page 6681 4. Install the J 44551 -5 screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551 -5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. IMPORTANT:Correct placement of J 44551 -5 is critical. 6. Remove the J 44551 -5 suction screen tool from the suction hose. 7. Install an A/C refrigerant filter. IMPORTANT:After a major compressor failure, you should also install an A/C refrigerant filter. 8. Install the J 44551 -1 suction screen notification label. Replacement SUCTION SCREEN REPLACEMENT TOOLS REQUIRED - J 42220 Universal Leak Detection Lamp - J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the A/C compressor hose assembly bolt. 3. Separate the A/C compressor hose assembly from the A/C compressor. 4. Select the proper size removal tool (1) from J 44551. IMPORTANT:The suction screens are available in 3 different sizes. 5. Remove the suction screen using the J 44551 -31 suction screen removal tool. 5.1. Thread the forcing screw into the suction screen. 5.2. Tighten the nut on the forcing screw to remove the suction screen. Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. 3. Test the circuit operation. Locations Ignition Control Module: Locations Engine Generator And Starter Page 5656 C117 (Engine Harness To AIR Harness, w/ California Emissions) Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 2187 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Page 1484 6. Install the camshaft retainer and bolts. Tighten the camshaft retainer bolts to 12 Nm (106 inch lbs.). 7. Install the balance shaft drive gear. Refer to Balance Shaft Installation for alignment of the balance shaft drive gear and the driven gear. 8. Install the valve lifters. 9. Install the timing chain and camshaft sprocket. Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Lift upward on the accelerator pedal in order to relieve tension on the cable. 3. Remove the retainer from the pedal lever hole by compressing the tabs on the retainer. 4. Remove cable from the slot in the pedal lever (1). 5. Remove the accelerator pedal mounting nuts (2). 6. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE IMPORTANT: The accelerator cable must not be kinked or damaged in any way during installation. Ensure that the mounting surface between the accelerator pedal assembly and the bulkhead is free of insulation. The carpet and padding in the pedal area must be positioned to lay flat and be free of wrinkles and bunches. Wire, hoses, cables, and other flexible components should not be within 13 mm (0.52 in) of the cable or lever, at any point in their travel. Page 3220 8. Connect the TP sensor harness connector. 9. Connect the IAC valve harness connector. 10. Install the air cleaner adapter stud. Tighten Tighten the stud to 8 N.m (71 lb in). 11. Install the air cleaner outlet duct. 12. Use the following procedure in order to inspect the accelerator pedal operation. 12.1. Turn ON the ignition, with the engine OFF. 12.2. Use a scan tool in order to observe the parameter for the TP sensor. 12.3. Depress the accelerator pedal to the floor. 12.4. Release the accelerator pedal. Page 7060 Locations SIR Components Service and Repair Wiper Control Module: Service and Repair WIPER MOTOR MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cover and three screws. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Page 2661 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 8399 WA9792/39 - WA990A/19U Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Parts ID Label Location The vehicle service parts identification label is located inside the instrument panel I/P compartment. The label is used to help identify the vehicle original parts and options. Page 262 Seat Adjuster Switch - Driver C2 (w/ 8-Way, w/o Memory) Electronic Compass Calibration Compass: Service and Repair Electronic Compass Calibration ELECTRONIC COMPASS CALIBRATION COMPASS CALIBRATION 1. Turn ON the ignition. IMPORTANT: Before calibrating the compass, drive the vehicle to a area that is magnetically clean, and free of large metallic objects. 2. Press the MODE button in order to advance to the COMP/TEMP mode. 3. Simultaneously depress and hold the US/MET and MODE buttons until a C is displayed, in approximately 10 seconds. 4. Release both buttons. 5. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the C is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT 1. Locate your geographic location. IMPORTANT: Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 2. Turn ON the ignition, with the engine OFF. 3. Press the MODE button in order to advance to the COMP/TEMP mode. 4. With the DIC in the COMP/TEMP mode, simultaneously depress and hold the MODE and US/MET buttons until VAR CAL is displayed, in approximately 5 seconds. 5. Release both buttons. 6. Press the US/MET button in order to advance to the proper zone number. 7. Press the MODE button in order to enter and set the zone number. Page 3651 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Diagrams Rear Wiper/Washer And Endgate Window Release Switch Page 4647 ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Pitting in the caliper bore Assembly Procedure 1. Lubricate the following parts with clean brake fluid. ^ The piston ^ The piston seal ^ The brake caliper bore. Important: Ensure that the piston seal is not twisted in the brake caliper bore groove. 2. Install the piston seal. 3. Install the boot on the piston. 4. Install the piston in the caliper bore. Page 5038 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 9446 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 2565 Engine Generator And Starter Page 2773 Body Control Module (BCM) C2 Part 3 Page 9665 Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 4027 Page 4598 Brake Shoe: Service and Repair Brake Shoe Replacement Removal Procedure 1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel. 4. Remove the brake drum. 5. Using denatured alcohol, clean the rear brake shoes and the hardware. 6. Using non-lubricated, filtered compressed air, dry the rear brakes and hardware. 7. Remove the brake adjusting hardware. 8. Remove the park brake hardware. Page 7051 For vehicles repaired under warranty, use the table. Disclaimer Page 7811 Front Door Panel: Service and Repair Water Deflector Replacement - Door Water Deflector Replacement - Door Removal Procedure Waterproof deflectors are used in order to seal the door inner panel and prevent water from entering the body. The deflector is secured by a strip of adhesive between the water deflector and the door. 1. Remove the door trim panel. * Trim Panel Replacement - Side Front Door * Trim Panel Replacement - Side Rear Door (Utility) Trim Panel Replacement - Side Rear Door (Extended Cab P/U Only) 2. Remove the door speaker if equipped. * Speaker Replacement - Front Door * Speaker Replacement - Rear Door in Entertainment. 3. Remove the water deflector(s) from the door. 4. Remove the water deflector(s) from the rear side door. 5. Break the bond between the sealer and the door with a flat-bladed tool in order to remove the deflector(s). Installation Procedure Page 3152 5. Install the rear fuel pipe bracket retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten 1. Tighten the rear fuel pipe bracket bolt to 6 N.m (53 lb in). 2. Tighten the fuel pipe retainer nuts to 3 N.m (27 lb in). 3. Install the new O-ring seals on the engine compartment fuel feed and the return pipes. 4. Install the chassis fuel feed and return pipes (1) to the engine compartment fuel feed and return pipes. Tighten Tighten the fuel pipe fittings to 27 N.m (20 lb ft). 5. Connect the spark plug wires to the left side of the distributor. 6. Tighten the fuel filler cap. 7. Connect the negative battery cable. 8. Inspect for leaks. 8.1. Turn ON the ignition for 2 seconds. 8.2. Turn OFF the ignition for 10 seconds. 8.3. Turn ON the ignition. 8.4. Inspect for fuel leaks. 9. Install the air cleaner outlet duct. Page 5509 Equivalent - Decimal And Metric Part 2 Page 5374 Splice Pack SP100 Page 9852 Window Switch - LR Page 5731 C203 (Body Harness To IP Harness) Part 5 Page 6631 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 296 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement With RPO Code Zrx/Extreme W/CF5 SUNROOF SWITCH REPLACEMENT (ZRX/EXTREME W/CF5) REMOVAL PROCEDURE 1. With a medium flat-bladed tool, remove the motor/actuator service cover. 2. Remover the motor/actuator trim cover screw (2). 3. Lower the trim cover (5). 4. Remove the switch (4) from the cover. 5. Disconnect the motor/actuator electrical connector (3). 6. Remove the ground screw (3) and ground wire (2) from the header in behind the motor/actuator. Page 9153 Registered And Non-Registered Trademarks - Part 4 Page 9102 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 3. Remove the two screws from the rotor. 4. Remove the rotor. Page 259 Seat Adjuster Switch - Driver C1 (w/ 8-Way, w/o Memory) Part 1 Page 6857 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Page 6055 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 2100 1. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold. The stud installs in the front hole. 2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets. 3. From under the hood position the exhaust manifold by the engine. 4. Raise the vehicle to the proper height. 5. Working the wheelhouse opening, install the exhaust manifold. 6. Install the spark plug wire shields. 7. If reusing the fasteners, apply threadlock GM P/N 1234,5493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts and stud. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the exhaust manifold bolts and stud. 8.1. Tighten the exhaust manifold bolts and stud on the first pass to 15 Nm (11 ft. lbs.). 8.2. Tighten the exhaust manifold bolts and stud on the final pass to 30 Nm (22 ft. lbs.). 9. Install the spark plug wires to the spark plug wire retainers. 10. Install the spark plug wires onto the spark plugs. Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Raise and support the hood. 2. Remove the bolt from the right and the left vent grille end panels. 3. Lift up on the right and the left vent grille end panels to release the retaining clips. 4. Remove the right and the left vent grille end panels. 5. Remove the screws that secure the center vent grille panel to the cowl. 6. Remove the push-pin retainers that secure the center vent grille panel to the cowl. 7. Remove the center vent grille panel from the cowl. Installation Procedure Page 8961 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 5532 Abbreviations And Meanings - Part 11 Page 178 Powertrain Control Module (PCM) Connector C1 Part 4 Page 7373 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Fuse Block - Underhood Location View Locations Cabin Air Filter: Locations This vehicle does not use a factory installed Cabin Air Filter. Page 7652 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 374 2. Install the engine oil pressure sensor fitting, if removed. Tighten the engine oil pressure sensor fitting to 15 Nm (11 ft. lbs.). 3. Install the engine oil pressure sensor. Using the J41712, tighten the engine oil pressure sensor to 30 Nm (22 ft. lbs.). 4. Connect the engine oil pressure sensor electrical connector. 5. Install the distributor. 6. Check and adjust engine oil level. Page 2047 6. Open the heater inlet hose retaining clip above the right side valve cover. Use a flat bladed tool to open the clip from the bottom. 7. Remove the heater inlet hose from the vehicle. INSTALLATION PROCEDURE 1. Apply lubricant, GM P/N 9985662, to each end of the heater inlet hose. 2. Install the heater inlet hose to the vehicle. IMPORTANT:When installing new heater inlet hose, place the clamp on the hose before installing the hose to the vehicle. 3. Install the heater inlet hose to the intake manifold fitting. 4. Install the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Install the heater inlet hose to the heater core. 6. Install the heater inlet hose clamp using the J 38185 at the heater core. Page 1636 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the bolt. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the attaching bolt. Tighten the tensioner assembly bolt to 50 Nm (37 ft. lbs.). 3. Install the drive belt. Page 3096 Steps 4-5 Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 980 Drive Belt Falls Off Diagnosis Step 1 - 12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked may will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Page 6462 Instruments - Inaccurate/Erratic Compass Operation Compass: Customer Interest Instruments - Inaccurate/Erratic Compass Operation Bulletin No.: 03-08-49-008A Date: February 26, 2004 TECHNICAL Subject: Erratic or Inaccurate Compass Operation with Use of Power Sunroof (Replace Compass Sensor Mounting Bracket and Calibrate Compass) Models: 1999-2004 Chevrolet Blazer 1999-2004 GMC Jimmy 1999-2001 Oldsmobile Bravada with Roof, Sun, Glass Sliding, Electric (RPO CF5) and Console Roof Interior, Custom, Compass and Outside Temperature (RPO DK7) or Console Roof Interior, Deluxe (RPO DK8) Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 03-08-49-008 (Section 08 - Body and Accessories). Condition Some customers may comment that the compass is intermittently erratic or inaccurate while operating the power sunroof. The compass may stay erratic or inaccurate while the power sunroof is open. Cause The sunroof module cable may become magnetized with the operation of the sunroof, producing a false signal to the compass sensor. Correction Follow the service procedure below to relocate the compass sensor by replacing the compass sensor bracket. Compass Sensor Mounting Bracket Replacement Procedure 1. Remove the rearview mirror. 2. Remove the sunshades and the retainers. 3. Remove the right front assist handle. 4. Remove the windshield garnish moldings. 5. Remove the body lock pillar trim panels. Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 8411 1. Slide the memory seat module into the bracket until the module is seated. 2. Install the memory seat module and bracket to the seat adjuster frame assembly with 2 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the memory seat module retaining screws to 3 N.m (26 lb in). 3. Install the memory seat module harness connectors. 4. Install the front seat to the vehicle. Page 485 Disclaimer Page 9815 Abbreviations And Meanings - Part 1 Page 547 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 6497 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5368 C501 (Body Harness To LH Front Door Harness) (4-Door) Part 1 Page 1800 Balance Shaft: Specifications Balance Shaft Driven Gear Bolt First Pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 35 degrees Balance Shaft Retainer Bolt ................................................................................................................ ................................................ 12 Nm (106 inch lbs.) Balance Shaft Bearing Journal Diameter - Rear ..................................................................................................................... 38.085 - 38.100 mm (1.4994 - 1.500 inch) Bushing Bore Diameter - Rear .......................................................................................................................... 0.050 - 0.088 mm (0.0020 - 0.0035 inch) Page 4449 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 6663 3. Install the heater outlet hose to the water pump. 4. Install the heater outlet hose clamp using the J 38185 at the water pump. 5. Install the heater inlet hose to the intake manifold fitting. 6. Install the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 7. Install the outlet heater hose to the heater core. 8. Install the outlet heater hose clamp using the J 38185 at the heater core. 9. Install the heater outlet hose to the retaining clip at the engine water outlet. 10. Place the outlet heater hose in the retaining clip above the right side valve cover. 11. Close the retaining clip. Ensure that the clip locks. Page 5780 C500 (Body Harness To LF Door Harness) (W/O Power Locks/Windows) Page 7809 Notice: Refer to Fastener Notice in Service Precautions. 6. Insert the screw that retains the inside door handle bezel to the door trim panel. Tighten the screw to 1.9 N.m (17 lb in). Door Handle Bezel Replacement Door Handle Bezel Replacement Removal Procedure 1. Remove the door trim panel from the door. 2. Release the 4 tabs retaining the bezel to the trim panel. 3. Remove the bezel from the trim panel. Installation Procedure 1. Install the bezel to the door, ensuring that all 4 retaining tabs are fully seated. 2. Install the door trim panel to the door. Camber Description Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-I). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 752 Page 3722 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON (R) II transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 5336 C223 (IP Harness To Auxiliary Power Tray) (Extended Cab) Page 1753 29. Clean the lower intake manifold in cleaning solvent. 30. Dry the lower intake manifold with compressed air. 31. Inspect the lower intake manifold for the following: ^ Damage to the gasket sealing surfaces (1), (2) and (3) ^ Restricted cooling system passages (5) ^ Cracks or damage ^ Damage to the threaded bolt holes 32. If the intake manifold requires replacement refer to Intake Manifold Disassemble. Installation Procedure Notice: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage. 1. Apply a 4.0 mm (0.157 inch) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the cylinder head side of the lower intake manifold gasket at each end. Page 2980 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID The EVAP purge solenoid controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid opens when commanded ON by the control module. This normally closed solenoid is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The solenoid will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Page 8725 Door Lock Cylinder Switch - Front Passenger Page 8954 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1250 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 2709 Registered And Non-Registered Trademarks - Part 2 Page 2360 Disclaimer Page 6777 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Page 3978 14. A hidden yellow identification band indicates proper joint seating. 15. Inspect and fill the transmission fluid to the proper level. Page 7304 Registered And Non-Registered Trademarks - Part 3 Page 1104 Disclaimer Page 2458 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove air cleaner assembly. 3. Remove the spark plug wires from the distributor cap. - Twist each spark plug boot 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 4. Remove the electrical connector from the base of the distributor. 5. Remove the two screws that hold the distributor cap to the housing. 6. Discard the screws. 7. Remove the distributor cap from the housing. 8. Use a grease pencil in order to note the position of the rotor in relation to the distributor housing (1). 9. Mark the distributor housing and the intake manifold with a grease pencil. Page 6137 Ball Joint: Service and Repair Upper Ball Joint Upper Ball Joint Replacement ^ Tools Required J 23742 Ball Joint Separator Removal Procedure Caution: Refer to Floor Jack Caution in Service Precautions. 1. Raise and suitably support lower control arm with safety stands. Refer to Vehicle Lifting. 2. Because the weight of the vehicle is used to relieve spring tension on the upper control arm, position the floor stands between the spring seats and the ball joints of the lower control arms. 3. Remove the tire and wheel assembly. Notice: Support the caliper with a piece of wire to prevent damage to the brake line. 4. Remove the brake caliper. 5. Remove the cotter pin. 6. Remove wheel speed sensor electrical connector from upper control arm. 7. Disconnect wheel speed sensor electrical connector. 8. Remove the upper ball joint stud nut. 9. Separate the ball joint from the steering knuckle using J 23742. 10. Apply pressure on the tool until the stud breaks loose. 11. Remove the J 23742. 12. Pull the ball joint stud away from the steering knuckle. Page 9959 Tighten Tighten the screw to 3 N.m (27 lb in). 3. Connect the hoses to the washer pumps. 4. Connect the electrical connectors to the washer pumps. 5. Refill the washer solvent in the solvent container. 6. Close the hood. Emissions - SES/MIL Lamp ON/DTC P0410 Set Air Injection Pump: Technical Service Bulletins Emissions - SES/MIL Lamp ON/DTC P0410 Set Bulletin No.: 04-06-04-015A Date: November 28, 2006 TECHNICAL Subject: LN2, L43 or L35 Engine SES/MIL Light Illuminated, AIR Pump Ingesting Water and DTC P0410 Set (Replace AIR Pump and Inlet Hose Assembly) Models: 1999-2003 Chevrolet Blazer, S10 1999-2001 GMC Jimmy 1999-2003 GMC Sonoma 1999-2001 Oldsmobile Bravada with Vortec 2.2L I4 or 4.3L V6 Engine (VINs 4, 5, W - RPOs LN2, L43, L35) Supercede: This bulletin is being revised to remove a part number and change the two AIR pump part numbers in the Parts Information. Please discard Corporate Bulletin Number 04-06-04-015 (Section 06 Engine/Propulsion System). Condition Some customers may comment on the SES/MIL light being illuminated. Upon investigation, the technician may find a DTC P0410 indicating that there is a concern in the secondary air injection system. Cause Water may have collected in the AIR pump or the vent solenoid and frozen or corroded the pump. Correction Replace the AIR pump and install a new inlet hose and solenoid tube assembly using the following procedure: Raise the vehicle on a hoist. Remove the shield covering the AIR pump. Remove the hose and vacuum lines from the pump and solenoid. Remove the AIR pump inlet hose. Do not re-use the hose. Disconnect the electrical connectors from the pump and solenoid. Remove the pump mounting bolts and pump. Transfer the isolators from the old pump to the new pump. Install the new AIR pump and bolts to the vehicle. Tighten Tighten the bolts to 17 N.m (12.5 lb ft). Route the new hose assembly up between the engine and fender. The hose should come up near the area between the battery and the coolant bottle. Connect the new inlet hose to the pump inlet. Connect the old outlet hose to the pump outlet. Connect the electrical connector to the pump. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 7295 Abbreviations And Meanings - Part 21 Page 1093 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 5041 Registered And Non-Registered Trademarks - Part 3 Page 8555 Power Seat Motor: Service and Repair SEAT ADJUSTER MOTOR GUARD REPLACEMENT REMOVAL PROCEDURE 1. Remove the 2 screws securing the guard to the seat. 2. Remove the guard. INSTALLATION PROCEDURE 1. Position the guard on the front of the seat adjuster assembly. 2. Install the guard to the seat with the 2 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) Step 1 - 7 Page 7994 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Window Latch Replacement - Lift Gate Window Removal Procedure 1. Remove the liftgate trim panel. 2. Mark the location of the liftgate latch in order to ensure proper alignment during installation. 3. Disconnect the electrical connectors, as needed. 4. Remove the nuts that retain the liftgate window latch to the latch support. 5. Remove the liftgate window latch from the liftgate window latch support. Installation Procedure 1. Install the liftgate window latch. Ensure that the window latch is properly aligned with the marks made during disassembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the liftgate window latch to the latch support. Tighten the nuts to 10 N.m (88 lb in). 3. Connect the electrical connectors, as needed. 4. Install the liftgate trim panel. Page 784 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 8946 Page 6463 Page 461 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 8170 Scuff Plate: Service and Repair Door Sill Plate Replacement - End Gate Door Sill Plate Replacement - End Gate Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Use the J 38778 in order to remove the door sill trim plate from the vehicle. Installation Procedure Install the door sill trim plate to the vehicle. Align the retainers along the door sill and press into place. Page 8824 Tailgate Release Handle: Service and Repair Handle Replacement - Rear Door Inside Handle Replacement - Rear Door Inside Tools Required J 34940 Rivet Gun Removal Procedure 1. Open the endgate. 2. Remove the screws that retain the inside handle to the endgate handle assembly. 3. Drill out the rivets that retain the endgate handle assembly to the endgate. 4. Remove the endgate handle assembly from the endgate. Installation Procedure 1. Position the endgate handle assembly on the endgate. 2. Install the endgate handle assembly to the endgate with 2 rivets using a J 34940 . Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the inside handle to the endgate handle assembly. Tighten the screws to 2.8 N.m (25 lb in). Page 4825 Park Neutral Position (PNP) Switch Page 9489 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 4632 6. Install the brake caliper bolts. Tighten the brake caliper bolts to 31 Nm (23 ft. lbs.). 7. Install the NEW metal (copper) gaskets to the brake hope and the bolt. Notice: Refer to Brake Hose Installation Notice in Service Precautions. 8. Install the rear brake hose bolt. Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Page 3453 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) Page 9702 Conversion English/Metric Part 2 Page 868 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut, increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage D Height Measurement The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. Cross vehicle D heights should be within 18 mm (0.71 inch) for utilities and 30 mm (1.18 inch) for pickups without options QZ8 and V4A to be considered correct. Pickups with options QZ8 and V4A should be 0 mm to be considered correct 1. Place hand on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 3. Allow the vehicle to settle into position. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. 4. Measure the D height by measuring the distance between the rear axle tube or rear axle bracket on vehicles with 7300 GVW rating and the frame. 5. Repeat the jouncing operation 2 more times for a total of 3 times. 6. Use the highest and lowest measurements to calculate the average height. 7. The true D height dimension is the average of the highest and the lowest measurements. 8. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear leaf springs ^ Worn rear suspension components, such as leaf spring bushings. ^ Collision damage Page 8266 5. Install the latch to the door. 6. Install the water deflector. 7. Install the door trim panel. Page 5396 Location View Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left Removal Procedure 1. Disconnect the breather tube at the air cleaner outlet duct. 2. Remove the air cleaner outlet duct retaining wingnut. 3. Disconnect the IAT sensor harness connector. Page 6131 6.3. First observe, then scrape a scale, a screwdriver, or a fingernail across the cover. If the round housing is flush with or inside of the cover surface, replace the lower ball joint. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 7. For 4WD vehicles, place a J 8001 dial indicator (1) against the spindle in order to show vertical movement. 8. Pry between the lower control arm (2) and the outer bearing race (1) while reading the dial indicator. This shows vertical looseness in the lower ball joints. The lower ball joint may show some looseness. 9. If the dial indicator reading is more than 3.18 mm (0.125 inch), replace the lower ball joint. 10. If the lower ball joint is within specifications, and there is too much horizontal looseness, check the upper ball joint for wear. Page 9830 Abbreviations And Meanings - Part 16 Page 8696 Abbreviations And Meanings - Part 16 Page 3427 Spark Plug: Service and Repair SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 3715 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 4857 Page 8387 WA8555/41 - WA8555/41 Page 6287 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 6495 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 1 Page 4854 Page 8676 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 2452 5. Note the locating holes that the rotor was removed from: - The rotor screw holes (1) - The rotor locator pin holes (2) 6. Line up the square-cut hole in the vane wheel with the camshaft position (CMP) sensor. 7. Remove the two screws that hold the CMP sensor. 8. Discard the screws. Page 2311 Transfer Case (With RPO Code NP8) Harness Routing View Page 7222 Garage Door Opener Locator View Page 1177 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 5676 C211 (Steering Column Harness To Body Harness) Part 1 Page 2397 Steps 1-3 Page 698 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 9121 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Compressor Hose Assembly Hose/Line HVAC: Service and Repair Compressor Hose Assembly COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose assembly bolt (1) and the washer (2). 3. Remove the compressor hose assembly from the compressor. 4. Remove the sealing washers. 5. Remove the compressor hose assembly from the accumulator. 6. Remove the O-ring seal and discard. 7. Remove the lower radiator hose. Page 7242 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition 1 voltage and the IPC flashes the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and request the IPC to turn the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a diagnostic trouble code (DTC) and request the IPC to turn the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Page 7103 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 2640 Page 5999 12. Connect the power steering cooler hose to the power steering pump. 13. Connect the power steering pressure hose to the power steering gear. 14. Install the power steering pump pulley. 15. Install the air cleaner assembly. 16. Remove the drain pan from under the vehicle. 17. Fill the power steering system. 18. Bleed the system. 19. Inspect the hoses for clearance away from the frame and other components. Page 9714 Abbreviations And Meanings - Part 4 Page 8462 7. Position the cover to the sunroof panel window garnish molding (3). IMPORTANT: Ensure the wires are positioned away from the trim cover attachment screw. 8. Install the motor/actuator trim cover screw (2). Tighten Tighten the screw to 1.5 N.m (13 lb in). 9. Install the motor/actuator service cover. Page 9347 Page 8678 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8024 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Door (ZR5) Emblem/Nameplate Replacement - Door (ZR5) Tools Required * J 25070 Heat Gun * J 41409 Body Molding Removal Tool Removal Procedure 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070. Apply heat using a circular motion for about 30 seconds. 3. Use a J 41409 to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 4. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 5. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water in order to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water in order to Page 2532 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 9478 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 1611 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Page 1261 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 3919 9. Push the range selector cable grommet up through the floor panel of the vehicle. 10. Lower the vehicle. 11. Remove the instrument panel trim and knee bolster. 12. Remove the door sill plate and the left hinge pillar trim panel. 13. Place the drivers seat in the most rearward position. 14. Pull back the carpet and insulation around the driver's area. Locations Electronic Components Page 9059 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. 8. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 9. Disconnect the I/P module yellow 2-way connector (1). Page 1017 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Page 131 Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Remove the blower motor relay (1) from the retaining bracket. 3. Disconnect the electrical connector. 4. Remove the blower motor relay. INSTALLATION PROCEDURE 1. Install the blower motor relay. 2. Connect the electrical connector. 3. Install the blower motor relay (1) to the retaining bracket. 4. Connect the negative battery cable. Page 2897 Engine Harness Rear (4.3L) Page 8390 WA8555/41 - WA8624/50 Page 4536 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Page 4337 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 764 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7296 Abbreviations And Meanings - Part 22 NV 1500 Transmission Speed Sensor: Service and Repair NV 1500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the vehicle speed sensor electrical connector. 3. Remove the vehicle speed sensor retaining bolt. 4. Remove the vehicle speed sensor. Installation Procedure 1. Install the new O-ring seal to the vehicle speed sensor. 2. Coat the new O-ring seal with a thin film of transmission fluid. 3. Install the vehicle speed sensor Notice: Refer to Fastener Notice in Service Precautions. 4. Install the vehicle speed sensor retaining bolt. ^ Tighten the vehicle speed sensor retaining bolt to 16 Nm (12 ft. lbs.). 5. Connect the vehicle speed sensor electrical connector. 6. Lower the vehicle. Page 3469 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side Page 6510 Abbreviations And Meanings - Part 11 Page 2507 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. 1. Remove the left instrument panel sound insulator from the vehicle. 2. Remove the lower instrument panel sound insulator from the vehicle. 3. Disconnect the electrical connectors from the body control module. 4. Bend the 2 snap retainers back slightly and pull the body control module from the bracket at an angle. INSTALLATION PROCEDURE 1. Install the body control module to the bracket at an angle under the wide hook retainer, with the label facing away from the bracket. 2. Apply pressure on the left side of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 3. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. 4. Connect the electrical connectors to the body control module. Be sure to connect the brown connector last. 5. Install the lower instrument panel sound insulator to the vehicle. 6. Install the left instrument panel sound insulator to the vehicle. 7. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The scan tool 8. Perform the BCM Programming. See: Testing and Inspection/Programming and Relearning 9. Clear the diagnostic trouble codes (DTCs). Page 6757 INSTALLATION PROCEDURE 1. Install the vacuum control assembly to the vehicle. 2. Install the vacuum control assembly retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to......................2 N.m (18 lb in). 3. Connect the vacuum harness connector to the vacuum control assembly. 4. Connect the electrical connector (4) to the vacuum control assembly (5). 5. Install the instrument panel carrier. Page 9123 Abbreviations And Meanings - Part 1 Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Diagrams Door Lock And Window Switch - Front Passenger C2 Page 5466 Disclaimer Air Deflector Replacement - Front Bumper Fascia (Pickups and Utilities) Air Dam: Service and Repair Air Deflector Replacement - Front Bumper Fascia (Pickups and Utilities) Air Deflector Replacement - Front Bumper Fascia (Pickups and Utilities) Removal Procedure 1. Remove the front bumper from the vehicle. 2. Remove the license plate bracket, if equipped. 3. Remove the push-in retainers from each end of the deflector. 4. Pull the air deflector retainers from the slots in the bumper. 5. Remove the deflector from the vehicle. 6. Remove the fog lamps from the deflector, if equipped. Refer to the appropriate procedure in Lighting Systems: * Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement * Fog Lamp Replacement - Front (Xtreme) Installation Procedure 1. Install the fog lamps to the deflector, if equipped. * Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement * Fog Lamp Replacement - Front (Xtreme) 2. Install the deflector to the vehicle. Ensure that the retainers lock into position. 3. Install the license plate bracket, if equipped. 4. Install 2 air deflector push-in retainers, one on either end of the deflector. 5. Install the front bumper to the vehicle. Page 7132 Abbreviations And Meanings - Part 25 Page 2879 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 4030 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 7651 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 5303 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 1 Page 2589 Powertrain Control Module (PCM) Connector C1 Part 2 Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Page 2650 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 8603 1. Install the recliner handle (1) to the seat bottom. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw to secure the handle. Tighten the handle retaining screw to 1.5 N.m (14 lb in). Seat Back Release Cable Replacement - Front Seat Back Release Cable Replacement - Front Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the seat back recliner handle. 3. Remove the 4 J-strips (1) securing the seat cover to the frame. 4. Remove spring (2) from the seat adjuster. 5. Pull the seat cushion pad and cover back to expose the frame. 6. Remove the 2 nuts (1) securing the seat adjuster rail to the frame. 7. Remove the cable (2) from the clip (1) on the adjuster rail. 8. Remove the cable (2) from the hole in the adjuster rail. 9. Remove the cable from the pass through hole (2) in the adjuster rail. Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 9641 Abbreviations And Meanings - Part 22 Page 4001 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 1383 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 4714 2. Install the park brake cable in the retainer and grommet. 3. Install the park brake cable on the park brake pedal. 4. Install the left trim-panel knee bolster. 5. Adjust the park brake cable. 6. Lower the vehicle. Refer to Vehicle Lifting. Page 3226 4. Remove the accelerator cable from the cable routing bracket. 5. Disconnect the accelerator cable (1) from the bracket clip (2). 6. Remove the left closeout/insulator panel. 7. Remove the accelerator cable from the accelerator pedal. 8. Remove the accelerator cable panel insulator retainer (2) from the accelerator cable (1). 9. Squeeze the accelerator cable tangs (3) and push the cable through the bulkhead (4). 10. Remove the accelerator cable. Page 2914 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 2 Page 1703 Oil Line: Specifications Remote Oil Filter Adapter Pipe Engine Oil Cooler Pipe Clip Bolt to Oil Pan ........................................................................................................................................... 9 Nm (80 inch lbs.) Remote Oil Filter Inlet and Outlet Hose Clip Bolt ................................................................................................................................ 10 Nm (89 inch lbs.) Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter Adapter Bolt ............................................................................................ 35 Nm (26 ft. lbs.) Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter Pipe Adapter Bolt .................................................................................... 35 Nm (26 ft. lbs.) Remote Oil Filter Pipe Clip Bolt to Oil Pan ............................................................................................................................................ 9 Nm (80 inch lbs.) Page 1219 Fuse Block - Underhood Connector C2 Part 2 Page 8705 Abbreviations And Meanings - Part 25 Page 3281 Crankshaft Position (CKP) Sensor Page 4923 Abbreviations And Meanings - Part 23 Page 750 Page 5592 Fuse Block - Underhood Connector C2 Part 1 Page 6022 3. Install the pitman shaft oil seal (2) and washer (3) to power steering gear. 4. Use J 6219 in order to seat the pitman shaft oil seal and the washer into the power steering gear. The seal should be in far enough to install the return ring, dust seal, and snap ring. 5. Install the return ring and dust seal to the power steering gear. 6. Use J 6219 in order to seat the return ring and dust seal into the power steering gear. 7. Install the snap ring (1) to the pitman arm shaft using J 4245. 8. Center the steering gear. 9. Line up steering gear to pitman arm. 10. Install the pitman arm. 11. Bleed the power steering system. Page 4060 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 5249 C203 (Body Harness To IP Harness) Part 4 Page 8688 Abbreviations And Meanings - Part 8 Page 9353 Tail Lamp: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6210 Trailing Arm: Service and Repair Tie Rod Replacement (ZR2 Models) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the rear axle at a curb height position. 3. Remove the following parts from the frame bracket: ^ The rear tie rod mounting bolt ^ The washers ^ The rear tie rod mounting nut 4. Remove the following parts from the axle bracket: ^ The rear tie rod mounting bolt ^ The washers ^ The rear tie rod mounting nut Page 8851 8. Remove the screws that secure the step panel to the forward and rear support brackets. 9. Remove the step panel from the side outer panel. 10. Remove the nuts that secure the forward and rear support brackets to the pickup box cross sills. INSTALLATION PROCEDURE Page 8127 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. Page 5727 C203 (Body Harness To IP Harness) Part 1 Page 9119 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 1773 27. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab. 28. Install the accelerator cable to the accelerator cable control bracket. Notice: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. Page 7375 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 5275 C301 (Dome Harness To Overhead Console) (w/o GDO) Page 8206 3. Using a flat-bladed tool, gently pry the coat hook plug (1) away from the trim panel (2). 4. Remove the shoulder belt opening trim cover. 5. Feed the seat belt through the trim cover. 6. Remove the body side trim panel from the vehicle. Installation Procedure 1. Feed the seat belt through the trim panel. 2. Install the shoulder belt opening trim cover. 3. Install the body side trim panel to the vehicle. Page 7589 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) Step 1 - 7 Page 4367 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 3331 7. Drill and punch out the two rivets holding the ignition coil to the bracket. 8. Remove the ignition coil from the bracket. INSTALLATION PROCEDURE 1. Install the ignition coil to the bracket with the 2 screws. IMPORTANT: A replacement ignition coil kit comes with 2 screws in order to attach the ignition coil to the bracket. 2. Install the ignition coil and the bracket to the intake manifold with studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 11 N.m (97 lb in). 3. Install the accelerator control bracket. Tighten Tighten the accelerator control cable bracket nuts and studs to 12 N.m (8.9 lb ft). Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. - After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 2649 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 3355 Engine Generator And Starter Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Specifications Piston: Specifications Pistons and Pins Piston - Piston to Bore Clearance - Production ................................................................................................. 0.018 - 0.061 mm (0.0007 - 0.0024 inch) Piston - Piston to Bore Clearance - Service ...................................................................................................................................................... 0.075 mm Page 6620 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. Page 4573 7. Remove the backing plate nuts. 8. Remove the backing plate from axle housing flange. Installation Procedure 1. Install the backing plate to the axle housing flange. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate nuts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 3. Install the park brake shoe. Page 5194 Relay Block - Body Part 4 Page 8458 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement With RPO Code CF5 SUNROOF SWITCH REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the driver information console (DIC). 2. Disconnect the electrical connector from the driver information display module. 3. Remove 6 screws securing the sunroof switch assembly to the DIC. 4. Remove the sunroof switch assembly from the DIC. INSTALLATION PROCEDURE Page 2593 Powertrain Control Module (PCM) Connector C2 Part 2 Page 9894 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Inner Removal Procedure 1. Remove the side front door trim panel. 2. Remove the staples that secure the sealing strip to the trim panel. 3. Remove the sealing strip. Installation Procedure 1. Position the sealing strip on the trim panel. 2. Install the sealing strip to the trim panel using the original staples or a heavy-duty staple gun. 3. Install the side front door trim panel. Page 5173 Fuse Block - Underhood Connector C1 Part 4 Page 6493 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 4885 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 1893 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 9387 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 3311 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. Page 3437 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 6083 Abbreviations And Meanings - Part 6 Page 5511 Arrows And Symbols Uses various symbols in order to describe different service operations Page 8362 Paint: Application and ID Parts ID Label Location The vehicle service parts identification label is located inside the instrument panel I/P compartment. The label is used to help identify the vehicle original parts and options. Page 2285 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 1242 Fuse Block: Application and ID Underhood Fuse Block Fuse Block - Underhood Details (Uplevel Utility) Application Table Part 1 Page 7078 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 9610 Conversion English/Metric Part 1 Page 3832 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Page 9617 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 1673 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Specifications Generator Usage Page 657 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Page 2518 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Testing and Inspection Ignition Cable: Testing and Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Description and Operation Fuel Filler Cap: Description and Operation NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over-tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement ^ Tools Required J 3049-A Valve Lifter Remover Removal Procedure 1. Remove the lower intake manifold. 2. Remove the valve rocker arms and the valve pushrods. Important: Place the components in a rack so that the components can be reinstalled to their original location. 3. Remove the bolts and valve lifter pushrod guide. Important: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters. 4. Remove the valve lifters. Important: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049-A for removal. Page 7081 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Locations Endgate Harness Routing View Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 9225 Engine Oil Pressure (EOP) Sensor Page 902 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover wingnuts. 2. Remove the air cleaner cover. 3. Remove the air cleaner element. 4. Clear out any debris in the air cleaner housing. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner housing. 2. Install the air cleaner cover. Page 9574 Specifications Power Steering Fluid: Specifications Fluid Type .......................... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent. Page 4490 7. Remove the caliper from the caliper anchor bracket. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol. 2. Dry the brake caliper pin bolts using non lubricated, compressed filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper bolts. 4. DO NOT apply the lubricant to the brake pad hardware. 5. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. Page 7433 Page 690 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Side Testing and Inspection Ball Joint: Testing and Inspection Ball Joint Inspection ^ Tools Required J 8001 Dial Indicator Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. ^ The upper control arm bumper must not contact the frame. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a floor stand or jack, as far outboard as possible, under the stabilizer bar bracket. Important: If a seal is cut or torn, replace the ball joint. 3. Clean and inspect the ball joints seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. 4. Check the wheel bearing for looseness. If looseness in the wheel bearing is present, refer to Wheel Bearings Diagnosis. 5. Check the ball joints for horizontal looseness. 5.1. Position the J8001 dial indicator against the lowest outboard point on the wheel rim. 5.2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in both joints. 5.3. The dial indicator reading should be no more than 2.00 mm (0.080 inch). If the reading is too high, check the lower ball joints for vertical looseness. Important: Do not support the lower control arm with a jack stand for a RWD vehicle, this will unload or cause compression on the wear indicator and will cause the wear indicator to give a false reading. 6. For RWD vehicles, check the lower ball joints for wear and for vertical looseness using the following procedure: 6.1. Remove the safety stand from under the lower control arm. 6.2. Inspect by sight the lower ball joint for wear. The position of the housing into which the grease fitting is threaded indicates wear. This round housing projects 1.27 mm (0.050 inch) beyond the surface of the ball joint cover on a new lower ball joint. Under normal wear, the surface of the ball joint housing retreats inward very slowly. Page 8106 1. Install the console to the vehicle. 2. Install the screws that retain the front of the console. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 7 N.m (63 lb in). 3. Install the cup holder insert. 4. Install the nuts that retain the rear of the console. Tighten Tighten the nuts to 10 N.m (89 lb in). 5. Install the transmission select switch (if equipped). CB Series Pump Locations View Page 7479 Speaker - LF Door Page 2623 Steps 16-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Page 9650 Registered And Non-Registered Trademarks - Part 4 Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve (1) from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose (2). 4. Disconnect the vacuum brake booster hose at the engine. 5. Remove the vacuum brake booster hose from the vehicle. Installation Procedure 1. Connect the vacuum brake booster hose at the engine. Page 8741 Seat Horizontal Position Sensor - Driver (w/ Memory) Page 6410 Wheel Fastener: Service and Repair Rear (Rear Drum Brakes) Wheel Stud Replacement (Rear Drum Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the brake drum. 4. Remove the wheel stud from the axle flange using J43631. Installation Procedure Page 4453 Page 5749 C219 (Left Inflatable Restraint Discriminating Sensor Jumper Harness to the Right Sensor Harness) (With RPO Code K18) Page 2705 Abbreviations And Meanings - Part 25 Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Cover Front Oil Seal Removal Procedure 1. Remove the crankshaft balancer. 2. Use a suitable prying tool to remove the crankshaft front oil seal. 3. Inspect the engine front cover seal bore for damage. 4. Inspect the crankshaft balancer seal area. Installation Procedure ^ Tools Required J 35468 Crankshaft Aligner/Seal Installer Important: The engine front cover is a plastic composition. 1. Lubricate the exterior of the crankshaft front oil seal with clean engine oil. 2. Use the J 35468 with a hammer in order to install the crankshaft front oil seal. 3. Inspect to ensure the crankshaft front oil seal is flush and square to the engine front cover. 4. Install the crankshaft balancer. Page 2637 Page 5717 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 1 Page 5358 C413 (Engate Harness To Body Harness) Page 1196 Application Table Part 3 Page 5644 C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 2 C101 (Body Harness To Engine Harness) Part 1 Page 7293 Abbreviations And Meanings - Part 19 Page 8554 Seat Recliner Motor - Driver (w/ Memory) Locations Low Pressure Sensor / Switch: Locations A/C Accumulator Page 1941 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 5456 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Specifications Fluid Pan: Specifications Oil pan to Transmission case bolt ............................................................................................................................................................. 11 Nm (97 in.lbs.) Page 4806 Front Frame Grounds Page 8109 1. Install the console wiring harness to the console. 2. Install the rear seat audio control to the console. 3. Install the amplifier from the console. 4. Install the compact disc player from the console. Important: Do not pinch the instrument panel to console wiring harness during this process. 5. Install the console to the vehicle by lifting the console (1) over and onto the floor studs. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the fasteners (2) that retain the console to the vehicle. Tighten the console to the vehicle retainers to 10 N.m (88 lb in). 7. Install the convenience tray to the armrest storage compartment. 8. Connect the instrument panel to console wiring harness connection 9. Install the passenger side toe-panel by firmly pressing the toe-panel into place. 10. Carefully press the wood shifter assembly close-out into place. The closeout panel will need to be rotated in order to fit over the shift handle 11. Install the front ashtray to the console by firmly pressing the ashtray into place. Page 5133 Abbreviations And Meanings - Part 26 Page 6805 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of 2 or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Page 95 Memory Seat Module - Driver C2 Part 2 Page 5052 Engine Generator And Starter Page 3529 Disclaimer Page 2201 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Page 9463 Page 6513 Abbreviations And Meanings - Part 14 Page 1647 6. Remove the bolts for the engine mount frame bracket. 7. Remove the engine mount frame bracket. 8. Remove the bolts holding the engine mount to the engine. 9. Remove the engine mount with the shield. Installation Procedure 1. Sub-assemble the engine mount, shield. and one bolt. Page 4548 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 8361 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Page 8347 WA8555/41 - WA8555/41 Page 7663 Conversion English/Metric Part 1 Page 1327 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 1537 3. Tighten the bolt until both locking wings draw tight against the inner wall of the engine block. Tighten the bolt to 1.9 Nm (17 inch lbs.). Important: The heater cord must not touch the following components: ^ The engine ^ The hot pipes ^ The manifold ^ Any moving components 4. Install the heater cord to the coolant heater. 5. Route the heater cord (2WD). Page 4493 8. Remove the front brake caliper piston seal. 9. Remove the bleeder valve from the brake caliper body. 10. Clean the following items with denatured alcohol. ^ The bleeder valve ^ The brake caliper body bore ^ The brake caliper piston Important: If the corrosion cannot be removed, replace the brake caliper housing and piston. 11. Using a crocus cloth, clean the corrosion from the brake caliper bore. 12. Dry the parts using non lubricated, filtered compressed air. 13. Replace the brake caliper or the piston if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Pitting in the caliper bore Assembly Procedure Page 3126 Fuel Meter Body Assembly 1. Lubricate the new O-rings with clean engine oil. 2. Install the regulator seal backup ring (15). 3. Install the regulator seal upper O-ring (16). 4. Install the regulator assembly filter (17). 5. Install the regulator seal lower O-ring (18). 6. Assemble the regulator with the vacuum tube pointing down into the regulator retainer clip. 7. Install the fuel pressure regulator retainer clip (13). 8. Install the upper manifold assembly. 9. Tighten the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 5000 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 7283 Abbreviations And Meanings - Part 9 Page 3597 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Page 9782 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 3617 Page 9386 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 3190 container regarding cleaner usage. - DO NOT use a cleaner containing an extremely powerful solvent such as methl ethyl ketone. - Shiny spots on the pintle and seat do not represent a bent or misaligned pintle shaft. - If heavy deposits are present in the air passage, remove the throttle body for a complete cleaning. 2. Replace the IAC valve O-ring. IMPORTANT: DO NOT reuse the original O-ring. INSTALLATION PROCEDURE 1. On a new IAC valve, measure the distance between the IAC valve pintle and mounting flange. Use finger pressure to slowly retract the pintle if the distance is more than 28 mm (1-1/8 in). IMPORTANT: Use an identical part when installing a new idle air control (IAC) valve. The IAC valve pintle shape and dimensions are designed for specific applications. 2. Lubricate the IAC valve O-ring with clean engine oil. 3. Align the flange holes with the mounting holes on the throttle body assembly. 4. Insert the IAC valve through the O-ring into the throttle body assembly. 5. Install the IAC valve mounting screws. Page 5126 Abbreviations And Meanings - Part 19 Page 4065 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 4789 3. Install the electrical connector. 4. Install the knee bolster trim panel. Page 5944 5. Remove the pitman arm from steering gear using J 6632-01 or J 29107-A. 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seals for excessive wear. 8. Clean the threads on the ball stud and the ball stud nut. Installation Procedure 1. Install the pitman arm to the pitman arm shaft. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the pitman arm washer and nut to the pitman arm shaft. Tighten the pitman arm shaft nut to 250 Nm (185 ft. lbs.). 3. Install the relay rod ball stud to the pitman arm. Ensure the seal is on the stud. 4. Seat the taper using J 29193 or J 29194. Page 4739 Installation Procedure 1. Install the brake pedal assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake pedal mounting bolts and the nut. Tighten the park brake pedal retaining bolts and the nut to 25 Nm (18 ft. lbs.). 3. Install the park brake cable to the brake pedal assembly. Important: Ensure that the brake cable retainer are expanded and are locked in the park brake pedal bracket 4. Install the front brake cable to the park brake pedal assembly. 5. Install the brake release handle. Page 4502 3. Remove the brake hose to brake caliper bolt. Important: The gaskets may be stuck to the brake caliper and/or the brake hose end. 4. Discard the metal gaskets. 5. Plug the opening in the front brake hose with a rubber plug in order to prevent brake fluid loss and contamination. 6. Remove the caliper guide pin bolts. 7. Remove the caliper from the caliper anchor bracket. Installation Procedure Page 4074 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Page 7699 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 9512 Abbreviations And Meanings - Part 8 Specifications Spare Tire: Specifications Spare Tire Carrier Mounting Bolts (4WD Utility) 22 ft. lbs. Spare Tire Carrier to Body Side Inner Panel Mounting Bolts (2-Door Utility) 22 ft. lbs. Spare Tire Carrier to Frame Mounting Nuts (4-Door Utility) 27 ft. lbs. Spare Tire Carrier to Rear Crossmenber Mounting Bolts (4-Door Utility) 100 inch lbs. Spare Tire Carrier to Rear Crossmember Mounting Nuts (Pickup) 19 ft. lbs. Spare Tire to Spare Tire Carrier Mounting Nuts (4WD Utility) 74 ft. lbs. Page 6779 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Page 7199 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) OnStar(R) - Number Incorrect/Incorrectly Assigned Cellular Phone: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 2303 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 4441 Page 5740 C209 (Dome Harness To Body Harness) Part 2 Page 4982 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Disc Brake Component Specs Page 9765 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Heater Hose - Inlet Heater Hose: Service and Repair Heater Hose - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Release the heater inlet hose clamp using the J 38185 at the heater core. 3. Remove the heater inlet hose from the heater core. 4. Release the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Remove the heater inlet hose from the intake manifold fitting. Page 495 Crankshaft Position (CKP) Sensor Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 379-427 kPa (55-62 psi) Page 3827 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 4496 Brake Caliper: Service and Repair Brake Caliper Replacement - Front (Single Piston) Brake Caliper Replacement - Front (Single Piston) Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, using an appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 6589 Compressor Clutch Hub: Service and Repair Installation V7 - Direct Mount COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (V7 - DIRECT MOUNT) TOOLS REQUIRED - J 33013-B Hub and Drive Plate Remover/Installer - J 33017 Pulley and Bearing Assembly Installer - J 33027-A Clutch Hub Holding Tool 1. Install the shaft key into the hub key groove (4) approximately 3.2 mm (1/8 in) out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove. 2. Clean the surfaces of the clutch plate (1) and the clutch rotor (2) before installing the clutch plate and hub assembly. 3. Align the shaft key with the shaft keyway in the clutch plate and the hub assembly and place onto the A/C compressor shaft (3). 4. Remove the J 33013-B. 4.1. Remove the center screw from the body of the J 33013-B. 4.2. Install the center screw into the opposite end of the J 33013-B. 5. Install the J 33013-B and bearing tools (1) onto the clutch plate (3) and the hub assembly (2). 5.1. Back the body of the J 33013-B off enough to allow the center screw to be threaded onto the end of the A/C compressor shaft. 5.2. Thread the center screw several turns onto the end of the A/C compressor shaft. Do not tighten the center screw on the A/C compressor shaft. Page 2696 Abbreviations And Meanings - Part 16 Page 7864 1. Install the latch to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower latch bolts. Tighten the lower latch bolts to 10 N.m (89 lb in). Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 7930 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 2708 Registered And Non-Registered Trademarks - Part 1 Specifications Crankshaft Seal Retainer: Specifications Crankshaft Rear Oil Seal Housing Bolt and Nut ................................................................................................................................. 12 Nm (106 inch lbs.) Crankshaft Rear Oil Seal Housing Retainer Stud .................................................................................................................................... 6 Nm (53 inch lbs.) Page 5301 C106 (Forward Lamp Harness To Body Harness) Part 1 Page 8388 WA8555/41 - WA8555/41 Locations Steering Column Components Page 5349 C310 (Sunroof Jumper Harness To Sunroof Harness) (ZRX/Extreme With RPO Code CF5) Page 2310 Automatic Transmission, RH Page 4210 10. Remove the old gasket material from the front bearing retainer. Installation Procedure Important: Inspect the bearing retainer for any nicks or cracks that may result in a leak. Replace if necessary. 1. Install the retaining ring on the input shaft bearing. Place the input shaft seal in the front bearing retainer. 2. Using the J 38801 install the input shaft seal. 3. Apply a thin layer of RTV sealer GM P/N 12345739 or equivalent to the mating surfaces of the input shaft bearing retainer. Notice: Refer to Fastener Notice in Service Precautions. Diagrams Door Lock And Window Switch - Front Passenger C2 Page 3350 4. Install the distributor. 5. Connect the negative battery cable. Page 952 Spark Plug: Specifications Spark Plug Torque Used heads 15 Nm 11 lb. ft. New aluminum heads 20 Nm 15 lb. ft. New iron heads 30 Nm 22 lb. ft. Page 7077 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 1725 6. Install the oil pan bolts and nuts. but do not tighten. 7. Measure the pan-to-transmission housing clearance using a feeler gage and a straight edge. Use a feeler gage to check the clearance between the oil pan-to-transmission housing measurement points. If the clearance exceeds 0.3 mm (0.011 inch) at any of the 3 oil pan-to-transmission housing measurement points (1), then repeat the step until the oil pan-to-transmission housing clearance is within the specification. The oil pan must always be forward of the rear face of the engine block. Notice: Refer to Fastener Notice in Service Precautions. 8. Tighten the oil pan bolts and nuts in sequence. Tighten the oil pan bolts to 25 Nm (18 ft. lbs.). 9. Measure the clearance between the 3 oil pan-to-transmission housing measurement points in order to ensure proper alignment. Page 5071 Service and Repair Crankshaft Position Timing Ring: Service and Repair Crankshaft Position (CKP) Reluctor Ring Replacement ^ Tools Required J 5590 Crankshaft Gear Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Installation Procedure Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the crankshaft position sensor reluctor ring. 1.1. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. 1.2. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 7107 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 8604 10. Remove the 2 bolts (1) from the seat back pivot assembly. 11. Remove the cable cover bracket (2). 12. Remove the cable (3) from the bracket (1) by loosening cable nut (2). 13. Remove cable (3). Installation Procedure 1. Install the cable (3) through the hole (2) in the seat adjuster rail. 2. Hook the cable (3) into the rail and clip the cable to the rail (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the seat adjuster rail to the seat frame with 2 nuts (1). Tighten the bolts to 24 N.m (18 lb ft) Page 6369 When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations Page 5994 inch). 4. Install the drive belt. 5. Install the fan clutch. Page 4858 Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 5871 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 5181 Fuse Block - Underhood Connector C2 Part 4 Page 8673 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 9408 Abbreviations And Meanings - Part 21 Page 3943 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8546 Seat Front Vertical Motor - Front Passenger (w/o Memory) Page 9622 Abbreviations And Meanings - Part 3 Page 2186 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Page 5182 Fuse Block - Underhood Connector C3 Part 1 Page 5504 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 9679 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 9851 Door Lock And Window Switch - Front Passenger C1 Part 2 Door Lock And Window Switch - Front Passenger C2 Page 978 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Drive Belt Chirping Diagnosis Step 1 - 15 Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the Page 3569 ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 8060 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (4 Door Utility) Frame Cushion or Insulator Replacement (4 Door Utility) Removal Procedure Important: Properly support the frame when you change the frame cushions. If only one cushion is changed, lower the entire side on which the cushion in placed in order to provide clearance for the cushion. 1. Raise the vehicle slightly on a hoist. Refer to Vehicle Lifting. 2. Place jack stands under the body on the side of the vehicle that the cushions will be placed. 3. Remove the frame cushion bolts. 4. Remove the retainer. 5. Remove the lower cushion. 6. Lower the hoist enough in order to leave the body supported by the jack stands. 7. Remove the upper cushion. 8. Remove the shims, if equipped. Installation Procedure 1. Install the shims, if equipped. 2. Install the upper cushion. Page 699 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 6477 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Bearing Clearance - Production .............................................................................................. 0.038 - 0.078 mm (0.0015 - 0.0031 inch) Connecting Rod Bearing Clearance - Service ................................................................................................... 0.025 - 0.063 mm (0.0010 - 0.0025 inch) Page 1111 Installation Procedure 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). Page 8730 Power Door Lock Switch: Service and Repair POWER ACCESSORY SWITCH PANEL REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the power accessory switch panel from the armrest. Use a flat-bladed tool in order to carefully pry the cover up at the front leading edge. 3. Disconnect the electrical connectors from the switch. 4. Remove the switches from the switch mounting panel, if necessary. INSTALLATION PROCEDURE 1. Install the switches to the switch mounting panel, if necessary. 2. Connect the electrical connectors to the switch. 3. Install the power accessory switch mounting panel to the armrest. Ensure that the retainers lock into place. 4. Connect the battery negative cable. Page 9140 Abbreviations And Meanings - Part 18 Locations Blower Motor Relay: Locations Body Wiring To Blower Motor And Resistor (With RPO Code C42) Page 7128 Abbreviations And Meanings - Part 21 Page 9732 Abbreviations And Meanings - Part 22 Page 6632 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 397 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 9621 Abbreviations And Meanings - Part 2 Page 884 Steps 15-17 Page 5365 C500 (Body Harness To LF Door Harness) (W/ Power Locks/Windows) Part 3 Page 9023 Audible Warnings Diagram 3 Page 8998 Abbreviations And Meanings - Part 10 Speaker Replacement - Front Speaker: Service and Repair Speaker Replacement - Front SPEAKER REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front speaker grille screws. 2. Remove the radio front speaker grille. 3. Remove the DRL sensor from the right speaker grille, if equipped. 4. Turn the DRL sensor counterclockwise 1/4 turn in order to remove. 5. Remove the radio front speaker screws. 6. Remove the radio front speaker. 7. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the radio front speaker. 3. Install the radio front speaker screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the radio front speaker screws to 1.9 N.m (17 lb in). 4. Install the DRL sensor to the right speaker grille, if equipped. Page 5004 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 4293 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the electrical connector from the sensor. 4. Remove the bolt (2). 5. Using a twisting and pulling motion, remove the vehicle speed sensor (1) from the case. 6. Remove and discard the O-ring seal (3). Installation Procedure 1. Install the new O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with clean transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Remove the drain pan. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 7065 Locations Floor Pedals Page 8258 Door Wiring Harness (RR Shown, LR Similar) Page 1102 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 6910 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Page 2762 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 5155 Application Table Part 2 Connector Views Fuse Block: Connector Views Fuse Block - I/P Part 1 Page 4906 Abbreviations And Meanings - Part 6 Page 435 Mass Air Flow (MAF) Sensor Description and Operation Air Bag Deactivation Indicator: Description and Operation INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH INDICATOR The instrument panel (I/P) module disable switch ON/OFF indicator is an LED located in a position that can been viewed by the occupants in the front seats. The location varies depending on the vehicle. When the I/P module disable switch is in the disable position, the I/P module disable switch indicator illuminates. When the I/P module disable switch is in the enable position, the I/P module disable switch indicator is not illuminated. The I/P module disable switch indicator will dim to a lower intensity when the headlamp switch is turned ON. Page 1235 Relay Block - Body Part 5 Page 7467 Controlling the Radio RDS can control the radio when data the receiver can use responds to timely information performing the following: - Interrupt the playback of your cassette or CD for traffic or emergency bulletins. - Search for stations by type of program. - Automatically follow networked programming from transmitter to transmitter as you travel from one listening area to another. - Set your clock to the time that the RDS Broadcast station broadcasts. Viewing and Selecting RDS Information for Display Press the "TUNE RCL" knob once for less then 2 seconds when the radio displays the program service name and the frequency of the station will be displayed. Press the knob again, and the program type (PTY) will be displayed. Pressed again, and the program name will be displayed (if the broadcaster is broadcasting one). The program name is an eight-character name that the broadcaster may use to further identify the type of programming currently being broadcast. Using the RDS Traffic Feature Some RDS broadcasters may carry traffic information programming to inform you of current traffic conditions in your listening area and is indicated by the icon in the radio display. RDS enables the broadcaster to get this information to you even when you are listening to a tape or compact disc. This feature can be enabled or disabled by the listener. Press the "TRAF" button to find a station that claims to carry traffic information. You may do this even when playing a cassette tape or compact disc. This action will operate in the background without interrupting the current playback. If the radio is not currently tuned to an RDS traffic station, the radio will immediately SEEK an RDS traffic station. If the radio finds an RDS traffic station, the" TRAF" icon will appear in the radio display as will brackets around the (TRAF) icon. If the radio cannot find an RDS traffic station after searching through the entire FM band, the radio will display "NO TRAFFIC". Alternate Frequency (AF) Switching RDS permits broadcaster's to send information to the radio that allows the radio to automatically switch frequency to the best quality station in that broadcaster's network. Since the radio is displaying the broadcaster call letters or nickname, the listener will not see the frequency during an AF switch unless you have changed the default display to be frequency instead of Program Service name. To enable or disable AF switching perform the following: Press and hold the AM/FM button for two seconds or more. - The radio will display AF ON or AF OFF depending on the current condition of AF and a confirmation beep will be heard. When AF is enabled and you recall a RDS station stored on preset, the radio determines if the station stored is of acceptable quality. If not, the radio checks all available AF's for your station. If the radio fails to locate your program, AF SEARCH will be displayed as the radio scans across the band looking for your program or an affiliated network. If the radio cannot find the original station or an acceptable alternate frequency NOT FOUND will be displayed and the radio returns to the original frequency for the preset. RDS Clock Time Broadcasters can choose to send clock time information in the RDS data. This information can be used to update the clock time on the radio. RDS clock time is broadcasted once a minute. To set the clock using RDS clock data perform the following: Press and hold the HR and MIN buttons together for two or more seconds to update the time. - The display will show UPDATED after receiving the broadcasted time data. - If the broadcaster is not broadcasting the time data, the radio will display NO UPDATE and the time remains unchanged. Description and Operation Door Switch: Description and Operation DOOR LATCH, DOOR JAMB SWITCHES The theft deterrent system uses the door latch switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. Page 5086 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 7062 Page 4962 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 3758 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Page 2960 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 3982 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Page 1166 Brake Bleeding: Service and Repair Manual Bleeding Procedure Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 5697 C315 (Body Harness To Passenger Seat Assembly Pigtail Connector) 4-Door with Power Seats) Page 8672 Conversion English/Metric Part 2 Page 6512 Abbreviations And Meanings - Part 13 Page 1179 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 3207 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 6715 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. See: Compressor HVAC/Service and Repair/Compressor Oil Balancing See: Service and Repair/Flushing Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. See: Specifications/Capacity Specifications Page 2626 NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the IAC valve are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 3 N.m (27 lb in). 6. Connect the IAC valve harness connector. 7. Install the air cleaner outlet resonator. 8. Perform the IAC Reset procedure: 8.1. Turn ON the ignition, with the engine OFF, for 5 seconds. 8.2. Turn OFF the ignition for 10 seconds. 8.3. Start the engine and check for proper idle speed. Page 8551 Seat Rear Vertical Motor - Driver Page 9832 Abbreviations And Meanings - Part 18 Page 851 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 7861 Rear Door Latch: Service and Repair Latch Replacement - Side Door Lower Latch Replacement - Side Door Lower Removal Procedure 1. Remove the door trim panel. 2. Slide the lower latch cover up the latch rod to access the latch rod retainer. Page 5119 Abbreviations And Meanings - Part 12 Page 5510 Equivalent - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1152 Refrigerant: Service Precautions DETECTOR PRECAUTION CAUTION: Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result. REFRIGERANT R-134A PRECAUTION CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Page 883 Steps 13-14 Page 6159 4. Remove the cotter pin. 5. Remove the tie rod end stud nut. 6. Disconnect the tie rod end from the steering knuckle using J 24319-B. 7. Remove the lower ball joint stud from the steering knuckle using J 23742. 8. Remove the upper ball joint stud from the steering knuckle using J 23742. 9. Raise the upper control arm. Disengage the ball joint stud from the steering knuckle. 10. Remove the steering knuckle from the lower ball joint stud. 10.1. Clean the steering knuckle. 10.2. Inspect the steering knuckle tapered hole. Replace the steering knuckle if this tapered hole is out-of-round, deformed, or damaged. Installation Procedure Page 4988 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 7290 Abbreviations And Meanings - Part 16 Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 8956 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1397 ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: ^ The load capacity ^ The wheel diameter ^ The rim width ^ The wheel offset ^ The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: ^ Wheel and hub-bearing life ^ Brake cooling ^ Speedometer/odometer calibration ^ Vehicle ground clearance ^ Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Page 1206 Fuse Block - I/P Part 2 Page 7697 Abbreviations And Meanings - Part 25 Page 9198 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Page 5787 C601 (Body Harness To Door Harness, RH Front) (W/O Power Locks/Windows) Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 8012 Rear Window Wiper Cutout And Liftglass Ajar Jamb Switch (Utility) Page 5886 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 7441 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Locations Clutch Switch: Locations Instrument Panel, LF Page 8567 Seat Adjuster Switch - Front Passenger (w/ 6-Way) Part 1 Seat Adjuster Switch - Front Passenger (w/ 6-Way) Part 2 ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Important: ^ Use the two-person bleed procedure under the following conditions: Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. Do not reuse brake fluid that is used during bleeding. - Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. 2. Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially filled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 660 4. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 5. Install the connector position assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 6. Install the off road skid plate, in equipped. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. Page 3863 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SM Caution In Service Precautions. 1. Disable the SIR system. 2. Remove the steering column trim covers. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Put the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam assembly. 6. Remove the automatic transmission shift lock control actuator. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket and the cable shift cam assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. Page 8602 Removal Procedure 1. Remove the recliner handle. 2. Remove the recliner cover. 3. Remove the inertia latch from the recliner assembly. 4. Remove the recliner assembly bolts. 5. Remove the recliner assembly from the seat. Installation Procedure 1. Install the recliner assembly to the seat. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the recliner assembly to the seat frame bolts. Tighten the recliner assembly to the seat frame bolts to 24 N.m (18 lb ft). 3. Install the inertia latch. 4. Install the recliner trim cover to the seat. 5. Install the recliner handle. Seat Back Recliner Handle Replacement - Front Seat Back Recliner Handle Replacement - Front Removal Procedure 1. Remove the handle retaining screw. 2. Remove the recliner handle (1) from the seat bottom. Installation Procedure Page 9844 Registered And Non-Registered Trademarks - Part 3 Page 1513 9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time. 10. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position. 11. Remove the balance shaft drive gear. Page 3923 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replace-Cnsle Shift Automatic Transmission Range Selector Cable Replacement (Console Shift) Removal Procedure 1. Apply the park brake. 2. Position the shift controller in the NEUTRAL position. 3. Raise the vehicle. 4. Disconnect the range selector cable (2) from the range selector lever ball stud (1). 5. Remove the positive assurance pin (2) from the bracket. 6. Remove the retainer (1) from the range selector cable and transmission bracket. 7. Depress the tangs and remove the range selector cable from the bracket. 8. Remove the transfer case shield, if equipped. Refer to the appropriate procedure: ^ Transfer Case Shield Replacement in Transfer Case-NVG 233-NP1 ^ Transfer Case Shield Replacement in Transfer Case-NVG 236-NP8 Page 5435 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 8639 Page 1905 9. Remove the CMP sensor. 10. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 11. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Drive out the roll pin with a suitable punch. 13. Remove the driven gear from the distributor shaft. Page 2769 Body Control Module (BCM) C1 Part 2 Locations Cruise Control Module (CCM) Locations Steering Column Components Intake Manifold Replacement - Lower Intake Manifold: Service and Repair Intake Manifold Replacement - Lower Intake Manifold Replacement - Lower Removal Procedure Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold. 1. Disconnect the negative battery cable. 2. Disconnect the breather tube at the air cleaner outlet duct. 3. Remove the air cleaner outlet duct. 4. Disconnect the accelerator cable from the throttle body. Page 6217 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: ^ General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle ^ Classify the failure of the wheel bearing with the aid of the illustrations. ^ Determine the cause of the wheel bearing failure. ^ Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 4495 5. Using J26267, install the front caliper piston boot.. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bleeder valve. Tighten the bleeder valve to 12 Nm (110 inch lbs.). Page 8576 Seat Lumbar Switch - Driver Part 2 Seat Lumbar Switch - Front Passenger Part 1 Page 2833 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 9528 Abbreviations And Meanings - Part 24 Page 1249 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 5773 C430 (Chassis Harness To License Lamp Harness) (Domestic) Page 5774 C430 (Chassis Harness To License Lamp Harness) (Export) Page 1815 5. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole). 6. Install camshaft sprocket bolts. Tighten the camshaft sprocket bolts to 25 Nm (18 ft. lbs.). 7. Install the crankshaft position sensor reluctor ring. 7.1. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. 7.2. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft Page 1123 3. Fill the transmission to the level of the fill plug hole. 4. Apply sealant to the oil fill plug threads. Use sealant GM P/N 12346004 or the equivalent. 5. Using J 36511 install the oil fill plug. ^ Tighten the oil fill plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Page 9159 Driver/Vehicle Information Display: Electrical Diagrams Driver Information System Diagram 1 Conditions For Wheel Replacement Wheels: Testing and Inspection Conditions For Wheel Replacement Replacement Wheels Description Replace the wheel if any of the following conditions exist: ^ The wheel exhibits excessive runout. ^ The wheel is bent. ^ The wheel is cracked. ^ The wheel is severely rusted. ^ The wheel is severely corroded. Important: Air leaks caused by porosity on aluminum wheels are repairable. ^ The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable if any of the following conditions exist: ^ The wheel has elongated bolt holes. ^ The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Page 8955 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8552 Seat Rear Vertical Motor - Front Passenger Page 7247 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 8778 Sunroof Opening Position Switch Page 3417 Knock Sensor (KS) Page 7071 Page 2926 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 9415 Registered And Non-Registered Trademarks - Part 1 Page 1180 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Spare Tire Carrier Replacement (2 Door RWD Utility) Spare Tire: Service and Repair Spare Tire Carrier Replacement (2 Door RWD Utility) Spare Tire Carrier Replacement (2 Door RWD Utility) Removal Procedure 1. Remove the spare tire cover. 2. Remove the spare tire from the spare tire carrier mounting nut. 3. Remove the spare tire from the spare tire carrier. 4. Remove the spare tire carrier to body side inner panel mounting bolts. 5. Remove the spare tire carrier from the vehicle. Installation Procedure 1. Install the spare tire carrier to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Page 2149 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C2 Powertrain Control Module (PCM) Connector C2 Part 1 Service and Repair Sunroof / Moonroof Frame: Service and Repair SUNROOF FRAME REPLACEMENT WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. Remove the sunroof panel window garnish molding. 2. Remove the screws (1) around the entire periphery of the lower frame (2). 3. Disconnect the electrical connector to the motor. 4. Remove the silver motor screw. 5. Carefully lower the rear of the frame and work the frame (2) from the front of the headliner. 6. Remove the lower frame (2) from the vehicle. 7. Remove the upper frame assembly from the vehicle. IMPORTANT: The upper frame assembly will need to have new foam tape applied to the outer ring prior to assembly. The new foam tape will ensure the sunroof will seal properly upon the lower frame installation. Page 6605 HVAC Control Assembly C3 Page 1168 Brake Bleeding: Service and Repair Pressure Bleeding Procedure Hydraulic Brake System Bleeding (Pressure) Tools Required ^ J29532 Diaphragm Type Brake Pressure Bleeder, or equivalent ^ J35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J29532, or equivalent, to the J35589-A. 8. Charge the J29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J35589-A. 23. Remove the J35589-A from the brake master cylinder reservoir. Service and Repair Cruise Control Servo Cable: Service and Repair CRUISE CONTROL CABLE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. Refer to Cruise Control Description and Operation for the complete operational details. 1. Open the hood. NOTE: Do not remove the C-clip from the cruise control connector. The C-clip was not designed for removal. Damage may occur when removing. 2. Do not remove the adjuster screw from the end of the cruise control cable. No adjustment will be needed. 3. Remove the cruise control cable from the throttle linkage. Use a suitable tool to lightly pry off the end of the cruise control cable from the stud on the throttle lever. Page 4964 Service Precautions Vehicle Lifting: Service Precautions CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Page 762 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 7273 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 6237 Vehicle Lifting: Service and Repair Vehicle Lifting Points VEHICLE LIFTING POINTS The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and Page 5682 C219 (Left Inflatable Restraint Discriminating Sensor Jumper Harness to the Right Sensor Harness) (With RPO Code K18) Page 7482 Speaker: Diagrams Speaker - LF (Utility) Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cooling fan. 3. Remove the drive belt. 5. Remove the engine wiring harness bracket from the generator mounting bracket. 6. Remove the drive belt tensioner. 7. Remove the drive belt idler pulley. 8. Remove the 3 bolts and nut holding the generator mounting bracket to the engine. 9. Remove the generator mounting bracket. INSTALLATION PROCEDURE 1. Install the generator mounting bracket to the cylinder head. 2. Install the 2 generator mounting bracket bolts and the nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the generator mounting bracket bolts and nut to 41 N.m (30 lb ft). Page 1987 Engine, LR Page 5544 Abbreviations And Meanings - Part 23 Page 5704 C412 (Endgate Harness To Body Harness) Fuse Block - Underhood Location View Page 274 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. Installation Procedure 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. Page 6467 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 5315 C203 (Body Harness To IP Harness) Part 3 Page 1148 Disclaimer Page 9561 Heated Glass Element: Removal and Replacement Rear Window Defogger Braided Lead Wire Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: * The rear defogger bus bar lead wire * The defogger terminal repair area Caution: Refer to Window Retention Caution in Service Precautions. Important: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 7. Align the spots with the flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: * The rear defogger bus bar lead wire * The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: * The top of the rear defogger bus bar lead wire Page 2791 Engine Control Module: Diagrams Powertrain Control Module (PCM) Connector C2 Powertrain Control Module (PCM) Connector C2 Part 1 Page 5287 C403 (Body Harness To LH Tail Lamp Harness) (Domestic) Page 6531 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 8622 5. Install the seat belt holder bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle bolt to 70 N.m (52 lb ft). 6. Install the seat back to seat bottom bolts. 7. Install the power seat control switch, if equipped. 8. Install the seat back release lever, if equipped. 9. Install the manual lumbar support knob, if equipped. 10. Connect the electrical connections, as needed. 11. Install the seat back recliner assembly, if equipped. 12. Install the cupholder and bracket, if equipped. 13. Engage the J-strips to the seat bottom frame. Diagrams Window Lockout Switch Page 3436 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 3105 Steps 8-12 Page 2099 12. Remove the fender wheelhouse extension. 13. Working through the wheel house opening disconnect the spark plug wires from the spark plugs. 13.1. Rotate the spark plug wire boot one half turn. 13.2. Pull outward on the spark plug wire boot to release from the spark plug. 14. Remove the exhaust manifold bolts and the stud. 15. Lower the vehicle. 16. From under the hood remove the exhaust manifold and the spark plug wire shields from the engine. 17. Remove and discard the exhaust manifold gaskets. 18. Clean all gasket surfaces. Installation Procedure Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place. Page 9449 Page 3069 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Page 2874 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 5167 Fuse Block - I/P Part 3 Page 182 Powertrain Control Module (PCM) Connector C2 Part 4 Page 4489 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake hose to brake caliper bolt. Important: The gaskets may be stuck to the brake caliper and/or the brake hose end. 4. Discard the metal gaskets. 5. Plug the opening in the front brake hose with a rubber plug in order to prevent brake fluid loss and contamination. 6. Remove the caliper guide pin bolts. Page 9509 Abbreviations And Meanings - Part 5 Page 2402 Steps 15-17 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 3203 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 8715 Seat Heater: Description and Operation HEATED SEATS DESCRIPTION AND OPERATION HEATED SEAT SYSTEM COMPONENTS The heated seats system consists of the following components: Heated seat switch - Driver heated seat relay module - Passenger heated seat relay module - Driver heated seat thermistor - Passenger heated seat thermistor - Driver back cushion heater element - Driver seat cushion heater element - Passenger back cushion heater element - Passenger seat cushion heater element - Passenger seat belt switch HEATED SEAT SYSTEM CONTROLS The heated seats are controlled by the following components: Headed seat switches - Heated seat modules - Passenger seat belt switch HEATED SEAT OPERATION Ignition voltage is supplied to the heated seat switches. When a heated seat switch is turned on, voltage is supplied through a resistor in the switch to the heated seat switch signal circuits and then to the heated seat module. Battery positive voltage and ground is supplied to the heated seat module for the heated seat elements. The seat heater module monitors the seat surface temperature through a thermistor located in the center of the seat back. With the heated seat switch turned on and the resistance through the heated seat thermistor within acceptable limits, the module closes an internal relay and battery positive voltage is then supplied to the seat heater elements. The passengers heated seat will not operate unless the seat belt is connected. This is a safety feature that ensures the seat will never remain ON. Locations Canister Purge Solenoid: Locations Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 2060 11. Remove the radiator. Installation Procedure Important: Inspect the rubber mounts before installing the radiator. 1. Install the radiator. 2. Install the transmission oil cooler lines to the radiator. 3. Install the engine oil cooler line to the radiator. 4. Install the radiator outlet hose to the radiator. 5. Using the J 38185 reposition the radiator outlet hose clamp to the radiator. 6. Install fan shroud. 7. Install the radiator inlet hose to the radiator. 8. Using the J 38185 reposition the radiator inlet hose clamp to the radiator. Page 2794 Powertrain Control Module (PCM) Connector C2 Part 4 Locations Throttle Position Sensor: Locations Engine, LR A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Page 9741 Registered And Non-Registered Trademarks - Part 4 Page 3622 ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. Page 9374 Equivalent - Decimal And Metric Part 1 Page 2103 23. Connect the breather tube to the air cleaner outlet duct. Page 5281 C307 (Body Harness To RR Door Harness) (4-Door) Page 7200 For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Antenna Cable: Service and Repair COAXIAL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the antenna mast. 2. Remove the radio antenna cable from the radio extension cable. 3. Remove the fender. 4. Remove the radio antenna cable nut. 5. Remove the radio antenna bezel. 6. Remove the radio antenna cable screws. 7. Remove the radio antenna cable. INSTALLATION PROCEDURE Page 2658 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 9145 Abbreviations And Meanings - Part 23 Page 5685 C229 (Body Harness To Dome Harness) Page 8544 Seat Lumbar Motor and Seat Recliner Motor (8-Way w/o Memory) Page 3814 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9078 Page 6173 Stabilizer Link: Service and Repair Rear Stabilizer Shaft Link Replacement (Pickup and 4-Door Utility) Stabilizer Shaft Link Replacement (Pickup and 4-Door Utility) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link upper nut and bolt. 3. Remove the stabilizer shaft link lower nut and bolt. 4. Remove the stabilizer shaft link Installation Procedure Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 3698 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5443 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Service Precautions Vehicle Lifting: Service Precautions CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Page 5638 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 6528 Registered And Non-Registered Trademarks - Part 2 Page 5308 C116 C2 (Engine Harness To Active Transfer Case Harness) Service and Repair Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Removal Procedure 1. Peel back the weatherstrip tape in order to reveal the molding screws. 2. Remove the fasteners. 3. Remove the reveal molding from the windshield pillar. Installation Procedure 1. Install the reveal molding to the windshield pillar. 2. Install the fasteners. 3. Install the new weatherstrip tape (if required). Page 9389 Abbreviations And Meanings - Part 2 Page 9954 Tighten Tighten the screw to 3 N.m (27 lb in). 3. Connect the hoses to the washer pumps. 4. Connect the electrical connectors to the washer pumps. 5. Refill the washer solvent in the solvent container. 6. Close the hood. Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 5257 C204 (Floor Shifter Harness To Body Harness) (Utility and Crew Cab) Page 8747 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (w/ 6-Way) Part 1 Page 5240 C116 C1 (Active Transfer Case Harness To Engine Harness) Page 8992 Abbreviations And Meanings - Part 4 Page 7665 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 3209 Throttle Position (TP) Sensor Engine Oil Cooler Hose/Pipe Replacement Oil Line: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement (2WD) Removal Procedure 1. Raise and the support vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil cooler line clamp bolt. Important: Have a drain pan ready for the engine oil to drain into. 3. Remove the bolt attaching the engine oil cooler lines to the oil filter adapter. 4. Remove and discard the seals. 5. Lower the vehicle. 6. Remove air cleaner assembly. Page 5040 Registered And Non-Registered Trademarks - Part 2 Locations Electronic Components Page 8777 Sunroof / Moonroof Switch: Diagrams Sunroof Motor (Sunroof Switch C1) Page 758 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1906 14. Remove the round washer. 15. Remove the tang washer. 16. Remove the shim washer (1). 17. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the CMP sensor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. Insert the sensor into the housing. Page 8780 Sunroof Switch C2 Page 5478 Page 5624 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 5847 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 335 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 3844 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 4776 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORX mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the E13CM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TOW screws (1) in the EBCM (2). Tighten the four T-25 TOW screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in. 1.52 mm Page 5599 Fuse Block - Underhood Connector C4 Part 1 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 7110 Abbreviations And Meanings - Part 3 Page 96 Memory Seat Module - Driver C3 Page 9629 Abbreviations And Meanings - Part 10 Page 9483 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 9995 1. Install the wiper motor onto the vehicle with three screws. Tighten Tighten the wiper motor mounting screws to 6.5 N.m (57 lb in). 2. Connect the electrical connector. IMPORTANT: Lubricate the socket with white lithium grease (GM P/N 9985885) or equivalent. - The wiper transmission must be assembled to the crank arm past the second detent so the seal is compressed to a maximum height of 25.5 mm (1 in). 1. Install the transmission drive link socket onto the crank arm ball of the wiper motor using the J 39529. 2. Install the air inlet grille panel. 3. Install the wiper arms. Service and Repair Axle Shaft Assembly: Service and Repair Rear Axle Shaft Replacement Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper, if equipped. 4. Remove the brake rotor, if equipped. 5. Remove the brake drum, if equipped. 6. Remove the rear cover and the gasket. 7. Remove the pinion shaft locking bolt. 8. On axles without a locking differential, remove the pinion shaft. Page 6639 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6204 Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement ^ Tools Required J 36202 Torsion Bar Loading/Unloading Tool Removal Procedure Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mark the adjuster bolt. 3. Install J 36202 to the adjustment arm and the crossmember. 4. Increase the tension on the adjustment arm until the load is removed from the adjuster bolt. Important: To aid in assembly, record the number of turns the tool makes when removing the adjuster bolt. 5. Remove the adjuster bolt and adjuster nut. 6. Remove J 36202 from the adjustment arm, allowing the torsion bar to unload. 7. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. 8. Remove the torsion bar support link upper mounting nuts. 9. Remove the torsion bar support link upper mounting bolts. 10. Remove the torsion bar support from the frame. Page 5658 Multiple Junction Connector: Diagrams C200 - C229 C200 (IP Harness To Body Harness) Engine Controls - Excessive Fuel Gauge Fluctuation Fuel Gauge: Customer Interest Engine Controls - Excessive Fuel Gauge Fluctuation Bulletin No.: 03-08-49-014A Date: October 02, 2003 TECHNICAL Subject: Fuel Gauge Fluctuates Between E and 1/4 Tank, Goes From 1/4 to Empty Too Quickly, Excessive Empty Fuel Reserve (Reprogram PCM) Models: 2001-2003 Chevrolet Blazer 2001 GMC Envoy 2001-2003 GMC Jimmy Supercede: This bulletin is being revised to add condition information. Please discard Corporate Bulletin Number 03-08-49-014 (Section 08 - Body and Accessories). This bulletin contains three different conditions depending on the model year of the vehicle involved. Condition # 1 (2001 4-Door Only) Some customers may comment that the fuel gauge goes from 1/4 to empty too quickly. Condition # 2 (2002 4-Door Only) Some customers may comment about excessive empty fuel reserve. Condition # 3 (2003 2-Door and 4-Door) Some customers may comment that the fuel gauge fluctuates between E and 1/4 tank. Correction Important: In order to select the correct calibration on some vehicles, you must first identify the cluster part number. This can be done using the Tech 2. DO NOT REMOVE THE CLUSTER. A new service calibration has been released to correct these conditions. Reprogram the PCM using the new service calibration, which was available from Techline starting August 25, 2003 on the TIS2000 version 9.0 or later. This calibration is an electronic calibration and is not available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 8687 Abbreviations And Meanings - Part 7 Page 9605 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 386 A/C Low Pressure Switch Page 5058 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Specifications Muffler: Specifications Hanger to Frame Bolts ........................................................................................................................ ...................................................... 17 Nm (13 ft. lbs.) Page 8438 Sunroof Components (ZRX, Extreme W/ CF5) Page 8138 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Page 1679 2. For a RWD vehicle, install the oil filter to the oil filter adapter. 3. For Four-Wheel Drive vehicles, install the oil filter to the remote oil filter adapter. 4. Tighten the oil filter following the instructions on the filter. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan drain plug into the oil pan. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the crankcase with the proper capacity and quality of engine oil. 8. Operate the engine and check for leaks and oil pressure. 9. For a Four-Wheel Drive vehicles, close the access panel in the steering linkage shield. Page 3721 Installation Procedure 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). Page 7100 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 5044 Starter Motor Usage Page 5154 Fuse: Application and ID Underhood Fuse Block Fuse Block - Underhood Details (Uplevel Utility) Application Table Part 1 Page 8176 1. Install the sunshade to the roof. 2. Install the sunshade retainer and the sunshade retainer screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.1 N.m (10 lb in). 3. Connect the electrical connections, if equipped. 4. Install the screws that retains the sunshade to the roof. Tighten Tighten the screws to 1.1 N.m (10 lb in). Page 6503 Abbreviations And Meanings - Part 4 Page 8701 Abbreviations And Meanings - Part 21 Page 4059 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 5474 Description and Operation Door Switch: Description and Operation DOOR LATCH, DOOR JAMB SWITCHES The theft deterrent system uses the door latch switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. Master Cylinder Bench Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 lbs.), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 7127 Abbreviations And Meanings - Part 20 Page 1335 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 4106 6. Position the clutch master cylinder into the cowl panel hole. 7. Turn the master cylinder 45 degrees counterclockwise to lock the master cylinder. 8. Connect the wiring harness to the clutch master cylinder start switch. 9. Connect the master cylinder rod to the clutch pedal. 10. Bleed the clutch. Page 7039 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 9056 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Raise and support the vehicle. 6. Remove the connector position assurance (CPA) from both inflatable restraints front end discriminating sensor connectors located on the frame crossmember. 7. Disconnect the inflatable restraints front end discriminating sensor connectors. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. Page 3369 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 5376 Splice Pack SP200 Part 1 Page 9674 Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Locations Left Hand Side Of Instrument Panel Page 6266 2. Install the spare tire carrier washers and the mounting bolts. Tighten the spare tire carrier mounting bolts to 30 Nm (22 ft. lbs.). 3. Install the spare tire to the spare tire carrier. 4. Install the spare tire to the spare tire carrier mounting nuts. Tighten the spare tire to the spare tire carrier mounting nuts to 100 Nm (74 ft. lbs.). Important: Close the carrier assembly firmly enough to engage both latches, or the spare tire carrier will rattle when the vehicle is in motion. 5. Close the spare tire carrier. Page 1316 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Wheel Speed Sensor Replacement (RWD Pickup) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor cable electrical connector (2). 6. Remove 13 mm bolt and nut fastening the wheel speed sensor harness clip to the front side of the upper control arm. 7. Remove clips from the wheel speed sensor wire. Save the clips for the sensor wire. 8. Remove two 13 mm wheel speed sensor mounting bolts (7). 9. Remove two 11 mm splash shield mounting bolts. 10. Remove wheel speed sensor and splash shield assembly (6). 11. Remove splash shield gasket. 12. Clean gasket and knuckle surfaces thoroughly with a dry cloth. Installation Procedure 1. Install splash shield gasket. 2. Install wheel speed sensor and splash shield assembly (6). Notice: Refer to Fastener Notice in Service Precautions. 3. Install two 11 mm splash shield mounting bolts. ^ Tighten the splash shield mounting bolts to 16 Nm (12 ft. lbs.). ^ Tighten the speed sensor mounting bolts (7) to 26 Nm (119 ft. lbs.). 4. Install harness clips to the wheel speed sensor wire. Page 8925 Cruise Control Module (CCM) Part 2 Page 4890 Arrows And Symbols Uses various symbols in order to describe different service operations Page 3379 Disclaimer Page 4660 Brake Fluid: Description and Operation Brake Fluid and Brake Fluid Handling Use extreme care when selecting brake system fluids or seal damage can result. Do not reuse brake system fluids. Do not mix power steering fluid with brake fluid. Fluid contamination may result in swelling and deterioration of rubber parts. This can lead to reduced brake performance and the eventual loss of braking capability. Service booster components in a clean work area separate from the brake servicing area. Wash hands before changing work areas. Do not use the same containers for brake and power steering fluids. Caution: Brake fluid may be irritating to the skin or the eyes, or may cause nausea, vomiting, or diarrhea if swallowed. In case of contact or swallowing take the following actions: ^ Eye contact - rinse thoroughly with water ^ Skin contact - wash with soap and water ^ if swallowed - Contact a physician immediately. Give two glasses of water and induce vomiting by sticking fingers down the throat. Notice: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills. Always store brake fluid in a closed, sealed container. Never use previously opened containers of stored brake fluid. Always use new brake fluid from a sealed container. Brake fluid left in open or improperly sealed containers will absorb moisture. Moisture can lower the brake fluid boiling point, causing the following problems: ^ Brake system contamination ^ Corrosion ^ Deterioration of rubber components Substandard Or Contaminated Brake Fluid It the brake fluid contains improper fluid, water, or other contaminates, the brake fluid may boil or may deteriorate rubber components in the hydraulic brake system. Evidence of rubber deterioration occurs in the following areas: ^ Swollen master cylinder piston seals ^ Swelling of the wheel cylinder boots ^ Swelling of caliper boots ^ Swelling of the master cylinder reservoir diaphragm If rubber deterioration is found, replace all rubber parts, including the hoses, in the brake system. Inspect for brake fluid on the brake linings. Replace the brake linings that are contaminated with brake fluid. If the brake fluid is contaminated and the master cylinder piston seals are good, check for leaks and excessive heat conditions. If no leaks or excessive heat conditions are found, flush the brake system. Flushing The Hydraulic Brake System In order to flush the brake hydraulic system, run new brake fluid through the brake system. Continue until the brake fluid at each bleeder valve comes out clear. Flushing is the only way to clean contaminated fluid out of the system. Flush the brake hydraulic system for the following reasons: ^ New hydraulic brake parts are installed ^ Contamination may be present ^ You do not know the grade of brake fluid in the brake system ^ Mineral oil is present in the brake fluid Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. TEST Page 7319 Page 7988 Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel Replacement - Lift Gate Trim Panel Replacement - Lift Gate Removal Procedure 1. Open the liftgate window. 2. Remove the screw retaining the liftgate trim panel to the liftgate window latch support. 3. Open the liftgate. 4. Remove the pullstrap. 5. Remove the trim panel from the liftgate. Installation Procedure 1. Install the trim panel to the liftgate. 2. Install the pullstrap. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw retaining the liftgate trim panel to the liftgate window latch support. Tighten the screw to 1.9 N.m (17 lb in). Page 8789 7. Position the cover to the sunroof panel window garnish molding (3). IMPORTANT: Ensure the wires are positioned away from the trim cover attachment screw. 8. Install the motor/actuator trim cover screw (2). Tighten Tighten the screw to 1.5 N.m (13 lb in). 9. Install the motor/actuator service cover. Page 4564 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal Injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km1h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Replacement - Front Brake Rotor Replacement - Front Tools Required ^ J42450-A Wheel Hub Resurfacing Kit Removal Procedure Important: The following service procedures applies to both 4 wheel and 2 wheel drive vehicles. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Notice: Refer to Brake Caliper Notice in Service Precautions. 3. Remove the brake caliper, 2 wheel drive vehicles. Page 6619 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. - For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 5141 Accessory Power Outlet - Right Description and Operation Security Lamp/Indicator: Description and Operation SECURITY INDICATOR The SECURITY indicator on the instrument cluster is controlled by the VTD system. The SECURITY indicator bulb is located inside the instrument cluster. The SECURITY indicator is controlled by the body control module through the class 2 data line. The VTD system contained in the BCM commands the instrument cluster to control the SECURITY indicator only when the ignition switch is ON. The VTD system uses the indicator as a malfunction indicator. Page 5732 C203 (Body Harness To IP Harness) Part 6 Page 7002 For vehicles repaired under warranty use, the table. Disclaimer Page 3490 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 5691 C303 (Power Seat Harness, RH To Power Recliner Harness, RH) (w/ Power Seats, Non-Memory) Page 3471 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 2104 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the exhaust pipe from the exhaust manifold. 3. Lower the vehicle. 4. Remove the bolt for the oil level indicator tube. Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged. 5. Remove the spark plug wires from the spark plugs. 5.1. Rotate the spark plug wire boot 1/2 turn. 5.2. Pull outward on the spark plug wire boot to release from the spark plug. 6. Remove the spark plug wires from the spark plug wire retainers. 7. Remove the exhaust manifold bolts. 8. Remove the spark plug wire shields and the exhaust manifold. 9. Remove and discard the exhaust manifold gaskets. 10. Clean all gasket surfaces. Installation Procedure Important: To assist in installing the exhaust manifold to the engine, the tabs at the bolt holes on a NEW exhaust manifold gasket will hold the bolts and the gaskets in place. Page 8111 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts that retain the console to the vehicle. Tighten the nuts to 10 N.m (88 lb in). 4. Install the storage compartment to the vehicle. 5. Install the trim plate to the console. 6. Install the screws that retain the trim plate to the console. Tighten the nuts to 1.9 N.m (17 lb in). 7. Install the cup holder insert. 8. Install the shift control lever. Page 549 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 2761 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 1563 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Page 6418 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Page 5244 Multiple Junction Connector: Diagrams C200 - C229 C200 (IP Harness To Body Harness) Page 4812 5. Locate the clip directly centered over the white paint mark on the wheel speed sensor cable. 6. Install harness clips and 13 mm fastening bolt and nut to the front side of the upper control arm 7. Install the hub and rotor. 8. Install brake caliper. 9. Install tire and wheel. 10. Lower the vehicle. Refer to Vehicle Lifting. Specifications Oil Level Sensor: Specifications Engine Oil Level Sensor ...................................................................................................................... ................................................ 13 Nm (115 inch lbs.) Page 940 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold - The cylinder head - The camshaft - The timing chain or sprockets - The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove air cleaner assembly. 3. Remove the spark plug wires from the distributor cap. - Twist each spark plug boot 1/2 turn. - Pull only on the wire boot in order to remove the wire from the distributor cap. 4. Remove the electrical connector from the base of the distributor. 5. Remove the two screws that hold the distributor cap to the housing. 6. Discard the screws. 7. Remove the distributor cap from the housing. 8. Use a grease pencil in order to note the position of the rotor in relation to the distributor housing (1). 9. Mark the distributor housing and the intake manifold with a grease pencil. Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOLS REQUIRED J 37088-A Fuel Line Quick-Connect Separator REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting. 3. Blow dirt out of the fitting using compressed air. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. 5. Pull the connection apart. 6. Using a clean shop towel, wipe off the male pipe end. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Page 8713 Seat Heater: Electrical Diagrams Heated Seats Diagram 1 Page 2821 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 5503 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2517 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Page 5744 C211 (Steering Column Harness To Body Harness) Part 2 Page 9707 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 1042 6. Open the heater inlet hose retaining clip above the right side valve cover. Use a flat bladed tool to open the clip from the bottom. 7. Remove the heater inlet hose from the vehicle. INSTALLATION PROCEDURE 1. Apply lubricant, GM P/N 9985662, to each end of the heater inlet hose. 2. Install the heater inlet hose to the vehicle. IMPORTANT:When installing new heater inlet hose, place the clamp on the hose before installing the hose to the vehicle. 3. Install the heater inlet hose to the intake manifold fitting. 4. Install the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Install the heater inlet hose to the heater core. 6. Install the heater inlet hose clamp using the J 38185 at the heater core. Page 2823 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Page 6569 3. Remove the clutch plate and hub assembly. 4. Using external snap ring pliers (1), remove the retaining ring (3) from the clutch rotor and bearing assembly. 5. Place J 33023-A on the clutch rotor. 6. Install J 41552 down into the inner circle of slots in the rotor. Turn J 41552 clockwise in the slots to engage the puller tangs with the rotor. 7. Hold J 41552 in place and use a wrench to turn the center forcing screw against J 33023-A to remove the clutch rotor and bearing assembly. Page 4630 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake hose to brake caliper bolt. Important: The gaskets may be stuck to the brake caliper and/or the brake hose end. 4. Discard the metal gaskets. 5. Plug the opening in the front brake hose with a rubber plug in order to prevent brake fluid loss and contamination. 6. Remove the caliper guide pin bolts. Page 4183 Flex Plate: Specifications Engine Flywheel Bolt Engine Flywheel Bolt ........................................................................................................................... .................................................. 100 Nm (74 ft. lbs.) Page 848 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 4798 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8136 4. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the I/P module yellow 2-way connector (1) located behind the I/P support. 6. Disconnect the I/P module yellow 2-way connector (1). Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the knee bolster. Page 9114 Conversion English/Metric Part 2 Page 9091 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 3487 Park Neutral Position (PNP) Switch Page 116 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 411 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the knee bolster trim panel. 2. Remove the electrical connector. 3. Remove the park brake warning lamp switch mounting bolt. Page 9671 Page 6358 ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: ^ The load capacity ^ The wheel diameter ^ The rim width ^ The wheel offset ^ The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: ^ Wheel and hub-bearing life ^ Brake cooling ^ Speedometer/odometer calibration ^ Vehicle ground clearance ^ Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Page 5270 C224 (Body Harness To Ashtray Insert) Page 7862 3. Disconnect the latch rod from retainer on the lower latch Page 5230 C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 2 C101 (Body Harness To Engine Harness) Part 1 Page 3568 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) Page 4911 Abbreviations And Meanings - Part 11 Page 8692 Abbreviations And Meanings - Part 12 Page 1909 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Gage Sensor ............................................................................................................................................................. 30 Nm (22 ft. lbs.) Engine Oil Pressure Gage Sensor Fitting - Plus Required Angle ............................................................................................................. 15 Nm (11 ft. lbs.) Diagrams Fuel Tank Pressure (FTP) Sensor Page 3337 Ignition Control Module (ICM) Page 5752 C229 (Body Harness To Dome Harness) Page 3345 Engine, LR Page 9744 Door Lock And Window Switch - Driver C1 Part 2 Page 5427 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Page 6688 3. Connect the heater hoses to the heater core. 4. Connect all of the vacuum lines to the heater assembly. 5. Connect all of the electrical connectors to the HVAC module. 6. Install the bottom right HVAC module mounting bolt from inside the vehicle approximately halfway into the threads. 7. On the Utility only, install the HVAC module mounting stud located at the lower right side of the heater core to heater hoses connection in the engine compartment. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the HVAC module mounting stud to ..........4.5 N.m (40 lb in). 8. Raise the vehicle. 9. On the Utility only, install the bottom right HVAC mounting studs. Ask an assistant to pull the bottom right corner of the HVAC module back from inside the vehicle. Tighten Tighten the heat/vent module mounting studs to .......4.5 N.m (40 lb in). 10. On the Utility only, install the A/C evaporator and blower module heat shield bracket. 11. Install the heater/vent module mounting nuts. Tighten Tighten the HVAC module mounting nuts to .......4.5 N.m (40 lb in). 12. On the Utility only, slide the A/C evaporator and blower module heat shield into the original position. 13. On the Utility only, install the A/C evaporator and blower module heat shield screws. Tighten Tighten the A/C evaporator and blower module heat shield screws ...............2.2 N.m (19 lb in). 14. Install the right front tire. 15. Install the bottom right HVAC module mounting bolt from inside the vehicle. Tighten Tighten the HVAC module mounting bolt to ................4.5 N.m (40 lb in). 16. Install the right wheel house panel. Page 8067 5. Install the catalytic converter hanger bracket to the transmission support mounting bolts, 4.3 L if necessary. Tighten the catalytic converter hanger bracket to the transmission support mounting bolts to 17 N.m (13 lb ft). 6. Install the catalytic converter hanger bracket to the transmission support mounting bolts, 2.2 L if necessary. Tighten the catalytic converter hanger bracket to the transmission support mounting bolts to 17 N.m (13 lb ft). 7. Install the transmission mount to the transmission support stud nut, 4.3 L pickup and utilities. Tighten the transmission mount to the transmission support stud nut to 45 N.m (33 lb ft). 8. Install the transmission mount to the transmission support stud nut, 2.2 L pickup. Page 1981 Fan Clutch: Service and Repair Fan Clutch Replacement ^ Tools Required J 46406 Fan Clutch Wrench Removal Procedure 1. Remove the upper fan shroud. 2. Remove the fan clutch from the water pump in a counterclockwise direction using the J 46406. 3. Remove the fan clutch assembly. 4. Remove the fan blade mounting bolts 5. Remove the fan blade from the fan clutch. Installation Procedure Garnish Molding Replacement Trim Panel: Service and Repair Garnish Molding Replacement Garnish Molding Replacement - Rear Upper GARNISH MOLDING REPLACEMENT - REAR UPPER TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Use the J 38778 in order to remove the rear header garnish molding. Insert the J 38778 and work along the front edge of the trim panel from one end to the other. 2. Remove the cargo lamp from the roof rear header garnish molding. INSTALLATION PROCEDURE 1. Install the cargo lamp from the roof to the rear header garnish molding. 2. install the roof rear header garnish molding to the vehicle. Garnish Molding Replacement - Side Door Lock Pillar RPO Code CF5 GARNISH MOLDING REPLACEMENT - SIDE DOOR LOCK PILLAR WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the front and rear door sill trim plates. 2. Remove the upper and lower front seat belt anchor bolts. Page 352 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (RWD Utility) Wheel Speed Sensor Replacement (RWD Utility) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. 9. Remove wheel speed sensor from hub and bearing assembly (5). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 4171 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement ^ Tools Required J 29117-A Wheel Bearing Cup Remover Removal Procedure 1. Raise and suitably support the vehicle with safety stands. 2. Remove the tire and the wheel. 3. Remove the brake caliper. 4. Remove the dust cap from the rotor. 5. Remove the cotter pin, the nut, and the washer. Notice: Do not damage the outer bearing and the spindle threads. 6. Remove the wheel hub and bearing from the spindle. 7. Remove the outer bearing. 8. Remove the seal. Pry the seal out and discard the seal. 9. Remove the inner bearing. 10. Clean all of the parts in a solvent, then air dry. Do not spin the bearings with compressed air. 11. Make sure all of the parts are clean and free of grease. 12. Inspect the rotor. 13. Inspect the bearings and the races for wear or damage. 14. Remove the inner and outer races using J 29117-A, if necessary. Installation Procedure Important: ^ Make sure that all of the parts are clean and free of grease. ^ Apply an approved high-temperature front wheel bearing grease to the spindle at the inner and outer bearing seat, the shoulder, and the seal seat. Page 8564 Seat Harness Routing (8-Way w/o Memory) OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 861 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 9166 Driver/Vehicle Information Display: Service and Repair Driver Information Center Replacement (Without Sunroof) DRIVER INFORMATION CENTER REPLACEMENT (WITHOUT SUNROOF) REMOVAL PROCEDURE 1. Remove the screw at the front of the console that retains the console to the roof. 2. Pull downward at the rear of the console in order to remove the console from the roof. 3. Disconnect the electrical connections as needed. INSTALLATION PROCEDURE 1. Connect the electrical connections as needed. 2. Insert the mounting tabs into the roof panel and push upward on the rear of the console in order to install the console to the roof. 3. Install the screw at the front of the console that retains the console to the roof. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 1.9 N.m (17 lb in). Page 3138 Steps 9-12 Page 5607 Relay Block - Body Part 3 Page 3222 Throttle Body: Service and Repair Throttle Body Cleaning Procedure 1. Remove the air cleaner outlet duct. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or an equivalent product. NOTE: Do not subject a throttle body assembly which contains the following components to an immersion cleaner or a strong solvent: Throttle position (TP) sensor - Idle air control (IAC) valve - Sealed throttle shaft bearings The cleaners will damage the electric components or sensors. The cleaners will damage some of these components that contain seals or O-rings. Solvents can wash away or break down the grease used on non-serviceable throttle shaft bearings. Never use a wire brush or scraper to clean the throttle body. A wire brush or sharp tools may damage the throttle body components. Do not use a cleaner that contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning. 1. If the deposits are excessive, remove and disassemble the throttle body for cleaning. Refer to the following procedures: - Throttle Body Assembly Replacement - Throttle Position (TP) Sensor Replacement - Idle Air Control (IAC) Valve Replacement 2. After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in any cleaning solvent. 3. If you removed and disassembled the throttle body for cleaning, assemble and install the throttle body. Refer to the following procedures: - Throttle Body Assembly Replacement - Throttle Position (TP) Sensor Replacement - Idle Air Control (IAC) Valve Replacement 4. Install the air cleaner outlet duct. Page 2566 Crankshaft Position (CKP) Sensor Page 3925 1. Install the cable through the opening in the floor panel. 2. Install the grommet to the floor panel. 3. Install the sound deadening material that covers the cable. 4. Install the cable to the controller. 5. Install the retainer securing the cable to the controller. 6. Connect the cable end to the controller ball stud. 7. Install the front mat and carpet. 8. Install the console. 9. Ensure that the shift controller is in the NEUTRAL position. 10. Raise the vehicle. 11. Install the range selector cable to the bracket. 12. Install the retainer (1) to the range selector cable and transmission bracket. Page 6545 Blower Motor Resistor: Service and Repair With RPO Code C60 BLOWER MOTOR RESISTOR ASSEMBLY REPLACEMENT (WITH RPO CODE C60) NOTE: Do not allow the metal coils of the blower resistor to become grounded to any metal surface. This may result in internal circuitry damage. 1. Remove the A/C control relay bracket with the relay. 2. Remove the blower resistor harness. 3. Remove the stud from the IP, if necessary. 4. Remove the blower motor resistor mounting screw. 5. Cut the access cover (1) from the case. Cut all four sides of the cover in order to remove the three attaching screws. Use a sharp utility knife in order to cut the case. Make the cuts straight and clean. The access cover must be reinstalled and is visible to the customer. 6. Remove the blower motor resistor assembly. INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly. 2. Install the blower motor resistor mounting screw. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screw to 1.9 N.m (17 lb in). 3. Utility only- Apply a bead of black weather-strip adhesive over the cut-line areas (1). 4. Utility only- Allow the adhesive to set for 15 minutes, or until the adhesive skins over. Page 4945 Clutch Start Switch Page 5540 Abbreviations And Meanings - Part 19 Fuse Block - Underhood Location View Page 2382 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 3229 10.4. Release the accelerator pedal. 10.5. Verify the throttle position has gone from 0 percent to 100 percent and back to 0 percent. IMPORTANT: The accelerator pedal should operate freely without binding between closed and wide open throttle. 11. Install the left closeout/insulator panel. Specifications Engine Mount: Specifications Engine Mount Bolt - Through-bolt ........................................................................................................................................................... 74 Nm (55 ft. lbs.) Engine Mount Bolt to Engine ................................................................................. .................................................................................. 54 Nm (40 ft. lbs.) Engine Mount Bracket Bolt to Frame ....................................................................................................................................................... 45 Nm (33 ft. lbs.) Engine Mount Nut - Through-bolt ............................................................................................................................................................ 63 Nm (46 ft. lbs.) Page 828 Door Lock And Window Switch - Front Passenger C1 Part 2 Door Lock And Window Switch - Front Passenger C2 Locations SIR Components Page 4352 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 2701 Abbreviations And Meanings - Part 21 Page 5639 For vehicles repaired under warranty, use the table. Disclaimer Page 8128 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Page 1674 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 631 Crankshaft Position (CKP) Sensor Page 7085 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 7606 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 2710 Registered And Non-Registered Trademarks - Part 3 Page 2647 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 2655 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 2873 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Page 1848 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Page 7496 Speaker: Service and Repair Speaker Replacement - Rear SPEAKER REPLACEMENT - REAR (UTILITY) TOOLS REQUIRED J 34940 Rivet Gun REMOVAL PROCEDURE 1. Remove the rear body side trim panel. 2. Remove the radio rear speaker retaining rivets. 3. Disconnect the electrical connector. 4. Remove the radio rear speaker from the rear body side trim panel. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the radio rear speaker to the body side inner panel. 3. Install the speaker retaining rivets using J 34940. 4. Install the rear body side trim panel. Body Side (Crew Cab) in Interior Trim. 5. Inspect for proper circuit operation. Page 4221 Page 4201 1. Apply sealant to the oil drain plug threads. Use Teflon (R) GM P/N 1052080, or the equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Use the J 36511 in order to install the oil drain plug. ^ Tighten the oil drain plug to 30 Nm (22 ft. lbs.). 3. Fill the transmission to the level of the fill plug hole. Page 5958 Power Steering Fluid Cooler: Service and Repair Power Steering Cooler Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the air cleaner assembly. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering cooler hoses from the power steering cooler. 4. Remove the Grille. 5. Remove the radiator air intake baffle retaining clips from LH side. 6. Position the radiator air intake baffle out of the way. Page 7121 Abbreviations And Meanings - Part 14 Page 5788 Splice Pack SP100 Page 3489 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 9855 2. Install the power window switch to the trim panel by pressing down. Ensure that the retainers lock into place. Page 2790 Powertrain Control Module (PCM) Connector C1 Part 4 Page 6160 1. Install the upper ball joint to the steering knuckle. 2. Install the lower ball joint to the steering knuckle. 3. Install the splash shield to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the splash shield bolts. Tighten the splash shield bolts to 26 Nm (19 ft. lbs.). 5. Install the tie rod end to the steering knuckle. Ensure that the seal is on the stud. 6. Seat the taper using J 29193. Tighten J 29193 to 54 Nm (40 ft. lbs.). Remove J 29193 from the tie rod end ball stud. 7. Install the tie rod end retaining nut. Tighten the tie rod end retaining nut to 53 Nm (39 ft. lbs.). 8. Install the rotor. 9. Lower the vehicle. 10. Check the front wheel alignment. Page 6661 Heater Hose: Service and Repair Heater Hose - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Release the outlet heater hose clamp using the J 38185 at the heater core. 3. Remove the outlet heater hose from the heater core. 4. Release the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Remove the heater inlet hose from the intake manifold fitting. 6. Release the heater outlet hose clamp using the J 38185 at the water pump. 7. Remove the heater outlet hose from the water pump. Page 1137 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -18° C (0° F) ..................................................................................................................................................... 5W-30 synthetic (preferred) , 0W-30 Page 5479 Diagrams Ambient Air Temperature Sensor (DIC) Electronic Components Electronic Components Page 6064 Equivalent - Decimal And Metric Part 1 Page 5237 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 2 Locations Data Link Connector: Locations Body Wiring Harness, DLC and RCDLR Description and Operation Compact Disc Player (CD): Description and Operation COMPACT DISC FEATURES Compact Disc Features Each item in the list below represents topics covered in detail below. AM/FM Reception - Theft Deterrent - Integral Multi Disc CD Changer (IMDX) - Radio Data System (RDS) AM/FM Reception Radio Signal The radio signal is sent from a broadcast station and is then received by an antenna. The strength of the signal received depends on the following: The power output (wattage) of the broadcasting station - The location of the vehicle (or receiver) relative to the broadcast tower. - Obstacles between the tower and the receiver - Atmospheric conditions - What band (AM or FM) the station is broadcasting - Type of antenna and the ground plane AM Reception The AM band has a lower frequency range than the FM band. These longer wavelengths: - Bend around Obstacles - Follow the curvature of the earth - May reflect off the ionosphere (skip) The AM frequencies have longer range due to the ground wave. The ground wave follows the curvature of the earth and is effected by its conductivity. Greater conductivity equates to less signal loss thus transmission over water is better than over land. The AM band has a range of 80-320 km (50-200 miles). FM Reception The shorter wavelengths of the higher frequency FM band: Reflect off obstacles - Are absorbed by the ground - Penetrate the ionosphere Broadcasts in the FM band are limited to "line of sight" reception which is typically 40 km (25 miles). Even when out of a direct line of sight, the signal may be reflected into areas that would be in a "shadow" otherwise. Factors which affect the line of sight include: Height of the broadcast antenna - Height of the receiving antenna - Terrain and buildings in the broadcast path Theft Deterrent Page 4072 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Page 9265 3. Install the electrical connector. 4. Install the knee bolster trim panel. Page 7964 Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Seal Replacement - Hood Rear Removal Procedure 1. Remove the screws securing the seal to the cowl. 2. Use a flat-bladed tool in order to carefully break the adhesive bond. 3. Remove the seal from the cowl plenum flange. 4. Clean the flange. Use a suitable solvent such as a mixture of 50 percent isopropyl alcohol and 50 percent water or high-flash naptha. 5. Dry the area thoroughly. Installation Procedure 1. Remove the liner from the adhesive strip. 2. Position the seal to the cowl plenum. 3. Press the seal into place. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws to secure the seal to the cowl. Tighten the cowl plenum seal screws to 1.9 N.m (17 lb in). Page 6499 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 9232 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille. 2. Lift the temperature sensor upward in order to remove the temperature sensor. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the temperature sensor by sliding the temperature sensor downward. 3. Install the radiator grille. Page 6106 Registered And Non-Registered Trademarks - Part 2 Page 2454 14. Remove the round washer. 15. Remove the tang washer. 16. Remove the shim washer (1). 17. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the CMP sensor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. Insert the sensor into the housing. Page 9182 Fuel Gauge: Description and Operation FUEL GAGE The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: - The PCM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the low fuel indicator illuminates. Page 2660 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7232 Page 3170 Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement (4-Door Lower) REMOVAL PROCEDURE 1. Drain the fuel tank. 2. Raise the vehicle. 3. Loosen the fuel fill hose clamp (1) at the fuel tank fill tube. 4. Remove the fuel fill hose (13). INSTALLATION PROCEDURE 1. Install the fuel fill hose (13) to the fuel tank and fuel fill tube (12). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fuel fill hose clamps to 2.5 N.m (22 lb in). 2. Lower the vehicle. 3. Remove the fuel fill cap and refill the fuel tank. 4. Install the fuel fill cap. Page 4870 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 9003 Abbreviations And Meanings - Part 15 Page 2595 Powertrain Control Module (PCM) Connector C2 Part 4 Page 3759 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Page 50 For vehicles repaired under warranty use, the table. Disclaimer Page 6052 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 2619 Steps 3-5 Page 88 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 9849 Door Lock And Window Switch - Driver C2 Page 4910 Abbreviations And Meanings - Part 10 Page 5580 Fuse Block - I/P Part 2 Page 2735 Knock Sensor (KS) With RPO Code C42 Blower Motor Resistor: Service and Repair With RPO Code C42 BLOWER MOTOR RESISTOR ASSEMBLY REPLACEMENT (WITH RPO CODE C42) REMOVAL PROCEDURE 1. Disconnect the electrical connector (3). 2. Remove the blower motor resistor mounting screws (1). 3. Remove the blower motor resistor (2) from the blower case. INSTALLATION PROCEDURE 1. Install the blower motor resistor (2) to the blower case. 2. Install the blower motor resistor mounting screws (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector (3). Page 9720 Abbreviations And Meanings - Part 10 Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. INSTALLATION PROCEDURE Page 3473 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important:: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1-7) in the valve body. Page 2738 4. Install the distributor. 5. Connect the negative battery cable. Page 5298 C101 (Body Harness To Engine Harness) Part 2 Page 9004 Abbreviations And Meanings - Part 16 Page 2504 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry, any door opened, the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch, door jamb switch - Passenger door latch, door jamb switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(tm) data from the Passlock(tm) sensor. If the Passlock(tm) data is correct, the BCM will pass theft. The BCM will then transmit the code password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(tm) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(tm) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Page 9000 Abbreviations And Meanings - Part 12 Page 1759 ^ The Ignition Control Module (ICM) (1) ^ The generator (4) 30. Connect the power brake booster vacuum hose. 31. Connect the vacuum hose to the intake manifold, if equipped with A/C. 32. Install the water pump inlet hose to the intake manifold. 33. Install the heater hose to the intake manifold. 34. Install the radiator inlet hose to the thermostat housing. 35. Install the cruise control cable, if equipped to the bracket and the throttle shaft. 36. Install the accelerator cable onto the throttle body. Page 1955 3. Install the hose to the coolant recovery reservoir. 4. Using the J 38185 reposition the hose clamp. 5. Install the Powertrain Control Module (PCM). 6. Add coolant to reservoir. Page 372 Engine Oil Pressure (EOP) Sensor Diagrams Idle Air Control (IAC) Valve Page 6076 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 1814 ^ Crankshaft sprocket keyway for wear Installation Procedure 1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline. 2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. 3. Use the J 5590 in order to install the crankshaft sprocket. Important: Install the camshaft sprocket with the alignment mark at the 6 o'clock position. 4. Install the camshaft sprocket and the camshaft timing chain. Page 9002 Abbreviations And Meanings - Part 14 Page 781 Arrows And Symbols Uses various symbols in order to describe different service operations Page 9613 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Specifications Power Steering Line/Hose: Specifications Power Steering Hose Clamps 18 inch lbs. Page 2185 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Page 5859 For vehicles repaired under warranty, use the table. Disclaimer Page 399 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 4540 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 4456 5. Locate the clip directly centered over the white paint mark on the wheel speed sensor cable. 6. Install harness clips and 13 mm fastening bolt and nut to the front side of the upper control arm 7. Install the hub and rotor. 8. Install brake caliper. 9. Install tire and wheel. 10. Lower the vehicle. Refer to Vehicle Lifting. Locations Throttle Position Sensor: Locations Engine, LR Page 965 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 267 Seat Lumbar Switch - Driver Part 2 Seat Lumbar Switch - Front Passenger Part 1 Page 9716 Abbreviations And Meanings - Part 6 Page 2639 Page 9625 Abbreviations And Meanings - Part 6 Page 8235 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 7145 Driver Information System Diagram 2 Page 3784 For vehicles repaired under warranty, use the table. Disclaimer Page 3228 5. Install the accelerator cable onto the throttle body. 6. Ensure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab. 7. Install the accelerator cable to the accelerator cable control bracket. 8. Install the accelerator cable to the cable routing bracket. 9. Install the air cleaner outlet duct. 10. Use the following procedure in order to inspect the accelerator pedal operation. 10.1. Turn ON the ignition, with the engine OFF. 10.2. Using a scan tool, observe the parameter for the throttle position (TP) sensor. 10.3. Depress the accelerator pedal to the floor. Page 4606 Wheel Cylinder: Specifications Wheel Cylinder Mounting Bolts 13 ft. lbs. Bleeder Valve 62 inch lbs. Page 9538 Heated Glass Element: Electrical Diagrams Defogger Diagram Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Page 7829 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door (Drip Channel) Weatherstrip Replacement - Front Door (Drip Channel) Removal Procedure 1. Open the door. 2. Remove the weatherstrip drip channel (3). Installation Procedure Important: Apply the drip channel in an environment free of dust or dirt that could come in contact with the sticky backing (2) and prevent proper adhesion. 1. Clean the area where the drip channel is to be mounted. Use a general purpose adhesive remover. 2. Clean the affected body area with wax and grease remover, and wipe with isopropyl alcohol. 3. Dry the area thoroughly. 4. Ensure the body area is at a temperature range of 21-41°C (80-105°F). 5. Ensure that the drip channel is at a temperature range of 21-41°C (80-105°F). 6. Install end of drip channel begining at the upper rear corner (4) of front side door opening frame, towards the windshield reveal molding flange (1) removing the tape backing as seal is applied. 7. When the drip channel is in position use a roller to firmly attach the tape to the entire contact surface. Page 5065 C100 - C119 Multiple Junction Connector: Diagrams C100 - C119 C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 1 Page 7194 For vehicles repaired under warranty use, the table. Disclaimer Page 1631 8. Avoid mix-positioning the drive belt by one or more grooves. 9. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed the fix pointer should align within the indentation on the drive belt tensioner. 10. With a used drive belt installed the fix pointer should not align past the index mark. Page 5039 Registered And Non-Registered Trademarks - Part 1 Service and Repair Tailgate Weatherstrip: Service and Repair Weatherstrip Replacement - End Gate Window Removal Procedure 1. Open the endgate. 2. Starting at the corner of the endgate flange, pull the weatherstrip molding from the endgate. Installation Procedure 1. Push the ends of the weatherstrip onto the endgate flange corners. 2. Push the weatherstrip molding onto the flange along the entire length of the endgate. Page 6224 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.03-0.13 mm (0.001-0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Page 5710 Multiple Junction Connector: Diagrams C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 1 Page 7681 Abbreviations And Meanings - Part 9 Page 9447 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 385 A/C Accumulator Page 3744 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 8101 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9590 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 533 Manifold Absolute Pressure (MAP) Sensor Page 4777 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 953 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ....................................................... ACDelco 41-948 Page 3720 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Page 8094 2. Install the cargo tie down hooks. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that retain the cargo tie down hooks to the floor. Tighten the bolts to 35 N.m (26 lb ft). 4. Install the endgate or the liftgate door sill trim plate. 5. Install the jack to the vehicle. 6. Install the body side trim panels, as necessary. 7. Install the rear seat floor filler trim panels. Carpet Replacement - Rear Panel Carpet Replacement - Rear Panel Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the rear window garnish molding. 2. Remove the jack storage cover. Page 1592 15. Remove the J 22794. 16. Install the spark plugs. 17. Install the valve rocker arms to the cylinder head. 18. Install the valve rocker arm cover. Page 4157 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 8786 1. Install the sunroof switch to the sunroof console with 6 screws. 2. Connect the electrical connector to the driver information display module. 3. Install the DIC. Page 3004 1. Install the new O-ring seals on the engine compartment EVAP, fuel feed, and the return pipes. 2. Connect the chassis EVAP, fuel feed, and return pipes (1) to the engine compartment fuel feed and return pipes. 3. Install the EVAP and fuel pipes into the retainer clip (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the retainer clip bolt. Tighten Tighten the fuel pipe retainer clip bolt to 30 N.m (22 lb ft). 5. Connect the EVAP pipe (1). 6. Install the transmission. 7. Tighten the fuel filler cap. 8. Connect the negative battery cable. 9. Inspect for leaks. 9.1. Turn ON the ignition for 2 seconds. 9.2. Turn OFF the ignition for 10 seconds. 9.3. Turn ON the ignition. 9.4. Inspect for fuel leaks. Page 5968 6. Install the connector and fitting assembly (4) to the pump housing (1). Install the pump mounting studs (2) to the pump housing (1). ^ Tighten the pump mounting studs (2) to 35 - 80 Nm (29 - 59 ft. lbs.). ^ Tighten the connector and fitting assembly (4) to 75 Nm (55 ft. lbs.). Page 8445 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement With RPO Code CF5 SUNROOF MOTOR/ACTUATOR REPLACEMENT WITH RPO CODE CF5 REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the straps that retain the wiring harness. 3. Disconnect the electrical connectors, as needed. 4. Remove the screws that retain the sunroof motor/actuator (1) to the sunroof assembly. 5. Remove the sunroof motor/actuator from the vehicle. IMPORTANT: Do not move the sunroof mechanism while the motor/actuator is not in place. INSTALLATION PROCEDURE 1. Install the sunroof motor/actuator (1) to the vehicle. 2. Install the screws that retain the sunroof motor/actuator (1) to the sunroof assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof motor/actuator screws to 3.5 N.m (31 lb in). 3. Connect the electrical connectors, as needed. 4. Install the straps that retain the wiring harness. 5. Install the headliner. Page 5777 C500 (Body Harness To LF Door Harness) (W/ Power Locks/Windows) Part 1 Page 9400 Abbreviations And Meanings - Part 13 Locations Relay Block - Body Relays, Except Envoy Page 6320 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 9439 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 4716 7. Remove the park brake cable mounting bracket. Installation Procedure 1. Install the park brake cable mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake cable mounting bracket bolt. Tighten the mounting bracket bolt to 17 Nm (12.6 ft. lbs.). 3. Install the rear cables to the mounting bracket by inserting the cable till all the retaining tabs snap into place. Page 1094 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 208 2. Install the SDM (2) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 12 N.m (106 lb in). 5. Install the SDM harness connector (3) to the SDM (2). 6. Install the CPA (4) to the SDM harness connector (3). 7. Tape the cut carpet to cover the SDM. 8. Install the floor console, if equipped. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. Page 2733 Engine, LR Page 9107 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 9595 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 2754 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 2 Page 3539 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Page 5961 8. Connect the power steering cooler hoses to the power steering cooler. Tighten the power steering cooler hoses to the power steering cooler clamps to 2 Nm (18 inch lbs.). 9. Remove the drain pan from under the vehicle. 10. Install the air cleaner assembly. 11. Bleed the power steering system. Page 2598 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The Powertrain Control Module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The Ignition Control (IC) - The Knock Sensor (KS) system - The Evaporative Emissions (EVAP) system - The Secondary Air Injection (AIR) system (if equipped) - The Exhaust Gas Recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the Malfunction Indicator Lamp (MIL). When the PCM detects a malfunction, the PCM stores a Diagnostic Trouble Code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. Page 2939 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 9685 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 3974 Transmission Cooler: Service and Repair Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Page 8400 Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Page 9363 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 5015 Abbreviations And Meanings - Part 4 Disc Brake Component Specifications Page 2146 Powertrain Control Module (PCM) Connector C1 Part 2 Page 5247 C203 (Body Harness To IP Harness) Part 2 Page 6036 Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 3551 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 2289 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 5582 Fuse Block - I/P Part 4 Page 5190 Fuse Block - Underhood Connector C6 Relay Block - Body Page 9348 Page 9094 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 9202 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 7865 3. Disconnect the latch rod from retainer on the lower latch. Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module (BCM) C1 Part 1 Page 5754 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 1 Page 6152 7. Remove the catalytic converter hanger bracket from the transmission support mounting bolts, 4.3 L if necessary. 8. Remove the transmission support to the frame nuts, bolts, and reinforcement, 2.2 L. 9. Remove the transmission support to the frame nuts, bolts, and reinforcement, 4.3 L pickup. 10. Remove the transmission support to the frame nuts, bolts, and reinforcements, utilities. 11. Remove the transmission support. Installation Procedure Page 8038 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Body Side - Lower Rear (Chevrolet) Molding Replacement - Rear Body Side - Lower Rear (Chevrolet) Tools Required J 25070Heat Gun Removal Procedure 1. Heat the body side molding using a J 25070. Hold the heat gun approximately 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or chip the paint. 2. Peel the body side molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel and the back of the body side molding using a 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 4. Clean the body panel using Varnish Makers and Painters (VMP) naphtha. Installation Procedure 1. Warm body panel with a heat lamp or heat gun to a minimum of 21°C (70°F). 2. Peel the backing from the front end of the body side molding. Important: Do not touch the adhesive backing. 3. Press the body side molding to the body while continuing to remove the backing. 4. Hand roll the body side molding to the body in order to ensure proper adhesion. Page 6110 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Controls Switch - Left Page 1568 6. Clean the components with cleaning solvent. 7. Dry the components with compressed air. 8. Inspect the valve rocker arm components for the following: ^ Valve rocker arm valve pushrod socket contact surface (1) The contact surface must be smooth with no scoring or excessive wear. ^ Valve rocker arm roller pivot for binding or damage (2) ^ Valve rocker arm valve stem contact surface (3) The contact surface should be smooth with no scoring or excessive wear. ^ Valve rocker arm bolt threads for damage (4) 9. Inspect the valve pushrods for the following: ^ Restriction of the oil passage (1) ^ Wear or scoring of the end contact surfaces (2) The end contact surfaces must be smooth with no scoring or excessive wear. ^ Shaft for bends (3) Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent. 10. Inspect the valve rocker support for excessive wear or damage. Page 2101 11. Install the fender wheelhouse extension. 12. Install the front tire. 13. Raise the vehicle. Refer to Vehicle Lifting. 14. Connect the exhaust pipe to the exhaust manifold. 15. Lower the vehicle. 16. Connect the ECT sensor electrical connector. 17. Install the radiator inlet hose support bracket and nut. ^ Tighten the radiator inlet hose support bracket nut to 36 Nm (27 ft. lbs.). 18. Install the intermediate steering shaft. Notice: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. Page 9724 Abbreviations And Meanings - Part 14 Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) Step 1 - 7 Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 3790 For vehicles repaired under warranty, use the table. Disclaimer Page 584 Engine Harness Rear (4.3L) Page 9559 - Hold the heat gun nozzle 25 mm (1 in) from the surface. - Heat the repair area for 2-3 minutes. IMPORTANT: Use J 25070 capable of 260°C (500°F) or equivalent. If you do not use a heat gun, allow at least 24 hours at an ambient temperature of 21-32°C (70-90°F) for complete curing of the repair materials. Do NOT physically disturb the repair area until after that time. The grid line will be electrically operative immediately after the repair. 5. Connect the electrical connector. 6. Test the grid line operation in order to verify the grid line repair. Rear Window Defogger Braided Lead Wire REAR WINDOW DEFOGGER BRAIDED LEAD WIRE 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. CAUTION: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: - The rear defogger bus bar lead wire - The defogger terminal repair area 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. CAUTION: Refer to Window Retention Caution in Service Precautions. IMPORTANT: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 7. Align the spots with the flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: - The rear defogger bus bar lead wire - The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: - The top of the rear defogger bus bar lead wire Page 8632 Page 2023 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 6344 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 2224 Disclaimer Page 1195 Application Table Part 2 Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Window Removal Procedure In order to remove the liftgate window weatherstrip from the pinch-weld flange, perform the following steps: 1. Open the liftgate window. 2. Firmly grip the weatherstrip. 3. Pull the weatherstrip. Installation Procedure 1. Open the liftgate window. 2. Push the weatherstrip onto the pinch-weld flange. Begin with the pre-formed corner at either upper corner of the liftgate window opening. 3. Completely seat the weather-strip around the liftgate window opening. Page 774 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 1512 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the balance shaft retainer and bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 4. Install the balance shaft driven gear onto the balance shaft. 5. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the balance shaft driven gear bolt. 6. Install the balance shaft driven gear bolt. 6.1. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Install the balance shaft driven gear bolt. Tighten the balance shaft driven gear bolt to 20 Nm (15 ft. lbs.). Using the J 36660-A rotate the balance shaft driven gear bolt an additional 35 degrees. 7. Remove the wrench from the balance shaft. 8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case. Page 1575 6. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. Important: A/C compressor and bracket removal is not necessary. 7. Remove the valve rocker arm cover bolts. 8. Remove the valve rocker arm cover bolt grommets. 9. Discard the valve rocker arm cover bolt grommets. 10. Remove the valve rocker arm cover. Page 6307 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Camber Description Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-I). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Electronic Brake Control Module (EBCM) Connector C1 Page 3757 Disclaimer Page 5100 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 7140 Driver/Vehicle Information Display: Connector Views Driver Information Center (DIC) C1 (w/ Trip Computer) Part 1 Page 3053 Disclaimer Page 3363 Camshaft Position (CMP) Sensor Page 4405 Hydraulic Control Assembly - Antilock Brakes: Description and Operation BPMV Hydraulic Flow This vehicle is equipped with the Kelsey-Hayes EBC325 antilock braking system. The vehicle is equipped with the following braking enhancement systems: ^ Antilock Brake System (ABS) ^ Dynamic Rear Proportioning (DRP) The following components are involved in the operation of the above systems: ^ Electronic Brake Control Module (EBCM) - The EBCM controls the system functions and detects failures. The ESCM contains the following components: System Relay - The system relay is internal to the EBCM. The system relay is energized when the ignition is ON. The system relay supplies battery positive voltage to the solenoid valves and to the pump motor. This voltage is referred to as system voltage. - Solenoids - The solenoids are commanded by the EBCM to operate the appropriate valves in the brake pressure modulator valve, ^ Brake Pressure Modulator Valve (BPMV) - The BPMV uses a 3-circuit configuration to control the left front wheel, the right front wheel, and the combined rear wheels. The BPMV directs fluid to the left front and right front wheels independently. The BPMV directs fluid to the two rear wheels on a single hydraulic circuit. The BPMV contains the following components: Pump Motor - Three isolation valves (one for each hydraulic circuit) - Three dump valves (one for each hydraulic circuit) - A front low-pressure accumulator - A rear low-pressure accumulator ^ Wheel Speed Sensors (WSS) - As the front wheels spin, a toothed ring located at each wheel hub interrupts a magnetic field in the wheel speed sensors. This causes the wheel speed sensors to generate an AC signal. The EBCM uses this AC signal to calculate the wheel speed. The wheel speed sensors are replaceable only as part of the wheel hub and bearing assemblies. Any imperfections in the toothed ring, such as a missing or damaged tooth, can cause an inaccurate WSS signal. ^ Vehicle Speed Sensor (VSS) - The input signal for rear wheel speed originates with the VSS. The Powertrain Control Module (PCM) receives rear wheel speed information from the VSS and supplies this information to the EBCM via a serial data message. Page 7266 Conversion English/Metric Part 2 Page 979 drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Step 1 - 6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Page 6590 6. Hold the center screw with a wrench. 6.1. Tighten the hex portion of the J 33013-B body several turns. 6.2. Remove the J 33013-B from the clutch plate and hub. 6.3. Make sure that the shaft key is still in place in the keyway. 7. Reinstall the J 33013-B. 8. Place a feeler gage between the clutch plate and the clutch rotor. 9. Tighten the hex portion of the J 33013-B until the air gap between the clutch plate and clutch rotor is 0.40 mm (0.015 in). IMPORTANT Make sure that the air gap is even all around the clutch plate and hub assembly. 10. Remove the J 33013-B. 11. Hold the clutch plate and hub assembly (2) with the J 33027-A. 12. Install the A/C compressor shaft nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nut to .......17.5 N.m (13 lb ft). 13. Spin the pulley rotor by hand to make sure the rotor is not rubbing against the clutch drive plate. 14. Remove the A/C compressor from the J 41790. 15. Install the A/C compressor into the vehicle. With RPO Code HT6/HD6/HU6 COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED J 33013-B Hub and Drive Plate Remover/Installer Page 941 10. Remove the mounting clamp hold down bolt. 11. Remove the distributor. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than 1 clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving proper rotor alignment during the distributor installation. INSTALLATION PROCEDURE 1 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the 2 marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). Page 5232 C101 (Body Harness To Engine Harness) Part 3 C102 (Body Harness To Engine Harness) Page 4998 Equivalent - Decimal And Metric Part 1 Page 2755 Heated Oxygen Sensor (HO2S), Bank 2 Sensor 1 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 8659 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 472 Disclaimer Page 8215 3. Install the right front door sill trim plate to the vehicle by snapping it into place. Trim Replacement - Third Pillar TRIM REPLACEMENT - THIRD PILLAR (4-DOOR UTILITY) REMOVAL PROCEDURE 1. Remove the rear door sill trim plate. 2. Remove the lower rear seat belt bolt. 3. Remove the body side lower trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the body side lower trim panel to the vehicle. 2. Install the lower seat belt bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 70 N.m (52 lb in). 3. Install the rear door sill trim plate. Trim Replacement - Third Pillar (4-Door Utility) Trim Replacement - Third Pillar (4-Door Utility) Removal Procedure Page 7349 Disclaimer Page 1054 5. Install the compressor hose assembly to the accumulator. Tighten Tighten the hose to...........................48 N.m (35 lb ft). 6. Install the sealing washers. 7. Install the compressor hose assembly to the compressor. 8. Install the compressor hose assembly washer (2) and the bolt (1). Tighten Tighten the bolt to..............................33 N.m (24 lb ft). 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the components using the J 39400-A. Page 2776 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry, any door opened, the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch, door jamb switch - Passenger door latch, door jamb switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(tm) data from the Passlock(tm) sensor. If the Passlock(tm) data is correct, the BCM will pass theft. The BCM will then transmit the code password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(tm) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(tm) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 234 Door Lock Cylinder Switch - Front Passenger Locations Electronic Components Page 8918 2. Slide the cruise control cable conduit over the ribbon. 2.1. Install the tangs to the cruise control module housing. 2.2. Ensure that the tangs snap securely into place. 3. Snap the cruise control cable engine-end fitting (2) over the stud (1) on the throttle cam lever. 4. Connect the cruise control cable conduit fitting to the round hole in the engine cable bracket. Ensure that the tabs snap securely into the hole. Locations Starter Solenoid: Locations Engine Generator And Starter Page 4927 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 4613 Brake Bleeding: Service and Repair Manual Bleeding Procedure Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 7703 Registered And Non-Registered Trademarks - Part 4 Page 4691 1. Bench bleed the master cylinder. 2. Install the master cylinder to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the master cylinder bolts and nuts. Tighten the nuts to 36 Nm (27 ft. lbs.). 4. Connect the brake pipes to the master cylinder. Tighten the pipe nuts to 30 Nm (22 ft. lbs.). 5. Bleed the hydraulic brake system. Page 7659 Equivalent - Decimal And Metric Part 1 Page 759 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 2620 Steps 6-9 Engine - Balance Shaft Rattling Noises (Cancellation) Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 3316 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). - If the rotor segment is not aligned with the number 1 mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. - In order to correct this condition, remove the distributor and reinstall the distributor. 8. Install the distributor mounting clamp bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the distributor clamp bolt to 25 N.m (18 lb ft). Page 2483 Mass Air Flow (MAF) Sensor Page 7063 Page 9375 Equivalent - Decimal And Metric Part 2 Page 5385 Splice Pack SP204 Part 3 Splice Pack SP401 Page 5814 2. Install the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Tighten Tighten the underhood fuse block to the underhood electrical center support bracket bolts to 7 N.m (62 lb in). 3. Attach the battery positive cable with bolt to the underhood electrical center. Tighten Tighten the battery positive cable to the underhood electrical center bolt to 10 N.m (89 lb in). 4. Replace the battery positive cable cover. 5. Connect battery negative cable. Page 9670 Page 9188 Fuel Gauge Sender: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 2331 Camshaft Position (CMP) Sensor Page 6536 Blower Motor Relay Page 2304 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 4879 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 2082 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 1733 2. Install the engine oil pressure sensor fitting, if removed. Tighten the engine oil pressure sensor fitting to 15 Nm (11 ft. lbs.). 3. Install the engine oil pressure sensor. Using the J41712, tighten the engine oil pressure sensor to 30 Nm (22 ft. lbs.). 4. Connect the engine oil pressure sensor electrical connector. 5. Install the distributor. 6. Check and adjust engine oil level. Page 2725 Steps 19-20 The numbers below refer to the step numbers on the diagnostic table. 2. A partial loss of communication in the class 2 serial data circuit uses a different procedure than a total loss of communication of the class 2 serial data circuit. 4. The following DTCs may be retrieved with a history status. These DTCs are not the cause of the present condition. - U1300 - U1301 - U1305 6. A State of Health DTC with a history status may be present along with a U1000 or U1255 with a current status. This indicates that the malfunction occurred when the ignition was on. 10. Normal class 2 serial data communication cannot take place until the body control module (BCM) sends the appropriate power mode message. If the BCM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 12. Normal class 2 serial data communication cannot take place until the body control module (BCM) sends the appropriate power mode message. If the BCM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 17. If there are no current DTCs that begin with the letter "U", the communication concern has been repaired. 18. The communication concern may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Common signal ground at terminal 5. The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Page 4329 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 5042 Registered And Non-Registered Trademarks - Part 4 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 4720 9. Disconnect the rear park brake cable from the park brake level, left side shown. 10. Collapse the park brake cable locking finger at the backing plate. 11. Remove the park brake cable from the backing plate. 12. Remove the rear park brake cable from the vehicle, Installation Procedure Important: When routing the cables through the guide loop, route the left side cable first. 1. Install the park brake cable in the chassis and rear axle housing retainers. Important: When performing the following service procedure, ensure that the locking fingers for the park brake cable are fully seated against the backing plate. 2. Install the rear park brake cable in the backing plate. 3. Install the park brake cable in the park brake level. Page 2324 Throttle Position (TP) Sensor Page 5569 Application Table Part 2 Page 2818 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the spark plug wires and ignition coil wire from the distributor. 2. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. 3. Remove the distributor cap screws. Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 7426 Page 1216 Fuse Block - Underhood Connector C1 Part 7 Page 3994 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 6339 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 2472 Spark Plug: Service and Repair SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 5323 C204 (Column Shifter Plug To Body Harness) Page 6680 Hose/Line HVAC: Service and Repair Suction Screen Installation SUCTION SCREEN INSTALLATION TOOL REQUIRED J 44551 Suction Screen Kit IMPORTANT:Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert J 44551 -6 sizing tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel (1) to J 44551 -5. Page 8252 Door Lock Cylinder Switch - Front Passenger Page 6699 Refrigerant: Service Precautions DETECTOR PRECAUTION CAUTION: Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result. REFRIGERANT R-134A PRECAUTION CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Page 3741 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 2272 Manifold Absolute Pressure (MAP) Sensor Page 5367 C501 (Body Harness To LF Door Harness) (2-Door Export) Part 1 Page 4537 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Adjustments Hood Latch: Adjustments Hood Latch Adjustment Inspection Procedure 1. Release the primary hood latch in order to inspect the operation of the pop-up spring. 2. Attempt to raise the hood while the hood is in the pop-up position. * The hood should raise without the hood striker binding against the latch. * The secondary latch should engage in order to prevent the hood from being raised. Adjustment Procedure 1. Remove the hood latch mounting bracket. 2. Loosen the nuts that retain the hood latch support to the hood latch mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 3. Move the hood latch from side to side until the striker enters the center of the latch assembly. Tighten the primary hood latch support bracket mounting bolts to 25 N.m (18 lb ft). Page 144 Location View Page 4814 1. Install sensor into the hub and bearing assembly (6). Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. 8. Lower the vehicle. Refer to Vehicle Lifting. Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 2522 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. Locations Oxygen Sensor: Locations Heated Oxygen Sensors (HO2S) Page 5538 Abbreviations And Meanings - Part 17 Page 195 Engine Generator And Starter Engine Controls - Excessive Fuel Gauge Fluctuation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Excessive Fuel Gauge Fluctuation Bulletin No.: 03-08-49-014A Date: October 02, 2003 TECHNICAL Subject: Fuel Gauge Fluctuates Between E and 1/4 Tank, Goes From 1/4 to Empty Too Quickly, Excessive Empty Fuel Reserve (Reprogram PCM) Models: 2001-2003 Chevrolet Blazer 2001 GMC Envoy 2001-2003 GMC Jimmy Supercede: This bulletin is being revised to add condition information. Please discard Corporate Bulletin Number 03-08-49-014 (Section 08 - Body and Accessories). This bulletin contains three different conditions depending on the model year of the vehicle involved. Condition # 1 (2001 4-Door Only) Some customers may comment that the fuel gauge goes from 1/4 to empty too quickly. Condition # 2 (2002 4-Door Only) Some customers may comment about excessive empty fuel reserve. Condition # 3 (2003 2-Door and 4-Door) Some customers may comment that the fuel gauge fluctuates between E and 1/4 tank. Correction Important: In order to select the correct calibration on some vehicles, you must first identify the cluster part number. This can be done using the Tech 2. DO NOT REMOVE THE CLUSTER. A new service calibration has been released to correct these conditions. Reprogram the PCM using the new service calibration, which was available from Techline starting August 25, 2003 on the TIS2000 version 9.0 or later. This calibration is an electronic calibration and is not available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 674 Clutch Switch: Service and Repair Clutch Start Switch Replacement Removal Procedure 1. Remove the plastic retainer tabs from the clutch start switch. 2. Remove the clutch start switch from the push rod. 3. Remove the connector from the switch. Installation Procedure 1. Install the connector to the clutch start switch switch. 2. Install the clutch start switch to the pushrod with the plastic tabs. 3. Install the push rod to the clutch pedal. Page 5657 C119 (4WAL/SIR Harness To AIR Jumper Harness) Page 4768 2. Install the vacuum brake booster check valve to the hose (2). 3. Install the vacuum brake booster hose clamp to the check valve. 4. Install the vacuum brake booster check valve (1) to the vacuum brake booster. Page 931 For vehicles repaired under warranty, use the table. Disclaimer Page 2033 4. Remove the upper fan shroud. 5. Lift the lower fan shroud just enough to disengage the locating tabs from the radiator. 6. Remove the lower fan shroud from the vehicle. Installation Procedure 1. Install the lower fan shroud in the vehicle. 1.1. Position the lower fan shroud against the radiator. 1.2. Engage the locating tabs by pushing down on the fan shroud. 2. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the upper fan shroud bolts. Tighten the bolts to 10 Nm (89 inch lbs.). Page 4862 Page 9007 Abbreviations And Meanings - Part 19 Page 8498 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the straps that retain the wiring harness. 3. Disconnect the electrical connectors, as needed. 4. Slide the sunroof control module (2) to the right in order to remove the sunroof control module from the vehicle. INSTALLATION PROCEDURE 1. Slide the sunroof control module (2) to the left in order to install the sunroof control module to the vehicle. 2. Connect the electrical connectors, as needed. 3. Install the straps that retain the wiring harness. 4. Install the headliner. Page 3280 Engine Generator And Starter Page 3407 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 8355 WA9260/74 - WA9260/74 Page 6610 3. Install the HVAC control assembly to the instrument panel. Ensure that all 4 retaining tabs lock into place. 4. Install the HVAC control assembly retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to..........1.9 N.m (17 lb in). 5. Install the instrument panel accessory trim plate. Page 4718 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Rear (RWD Pickups) Park Brake Cable Replacement - Rear (RWD Pickups) Tools Required ^ J37043 Park Brake Cable Release Tool Removal Procedure 1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the adjuster nut at the equalizer. 4. Remove the rear park brake cable from the park brake connector. 5. Remove the rear park brake cable adjuster from the equalizer. Page 5340 C301 (Dome Harness To Overhead Console) (W/ GDO) Part 1 Page 6357 Wheels: Testing and Inspection Wheel Mounting Surface Check Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203-229 mm (8-9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components Page 6111 Steering Wheel Controls Switch - Right Page 4557 1. Using the J42450-A, clean the hub flange, 4 wheel drive vehicles. 2. Install the brake rotor, 4 wheel drive shown. 3. Install the brake rotor and wheel bearings, 2 wheel drive vehicles only. Page 8560 Seat Rear Vertical Position Sensor - Driver (w/ Memory) Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 5180 Fuse Block - Underhood Connector C2 Part 3 Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement WIPER ARM BLADE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Do not allow the wiper arm to fall back and strike the windshield. 1. Lift the wiper arm until it locks in the vertical position. 2. Push in the locking tab of the wiper blade clip and pull downward on the wiper arm blade. 3. Remove the wiper blade from the inside radius of the wiper arm. 4. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. 2. Position the wiper blade in the inside radius of the wiper arm hook. Page 4913 Abbreviations And Meanings - Part 13 Page 6465 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 8461 7. Disconnect the main feed electrical connector (1). 8. Remove the sunroof switch from the vehicle. INSTALLATION PROCEDURE 1. Position the ground wire (2) to the header. 2. Install the ground screw (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ground screw to 1.5 N.m (13 lb in). 3. Connect the main feed electrical connector (1). 4. Connect the electrical connector (3). 5. Operate the function of the sunroof switch (4). 6. Install the switch into the motor/actuator trim cover (5). Page 2816 Camshaft Position (CMP) Sensor NV 1500 Transmission Speed Sensor: Service and Repair NV 1500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the vehicle speed sensor electrical connector. 3. Remove the vehicle speed sensor retaining bolt. 4. Remove the vehicle speed sensor. Installation Procedure 1. Install the new O-ring seal to the vehicle speed sensor. 2. Coat the new O-ring seal with a thin film of transmission fluid. 3. Install the vehicle speed sensor Notice: Refer to Fastener Notice in Service Precautions. 4. Install the vehicle speed sensor retaining bolt. ^ Tighten the vehicle speed sensor retaining bolt to 16 Nm (12 ft. lbs.). 5. Connect the vehicle speed sensor electrical connector. 6. Lower the vehicle. Page 9141 Abbreviations And Meanings - Part 19 Page 6858 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 5328 C210 (Body Harness To Redundant Steering Wheel Controls Harness) Locations Throttle Position Sensor: Locations Engine, LR Page 3344 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Specifications Coolant Outlet: Specifications Water Outlet Housing Bolt 2.2L ........................................................................................................................................................... 10 Nm (89 inch lbs.) Water Outlet Housing Bolts 4.3L ............................................................................................................................................................. 19 Nm (14 ft. lbs.) Page 728 Page 9399 Abbreviations And Meanings - Part 12 Page 9089 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5433 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9116 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 3888 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Page 2383 Engine, LR Distributor Ignition (DI) System Description Engine Control Module: Description and Operation Distributor Ignition (DI) System Description POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: The Throttle Position (TP) sensor - The Engine Coolant Temperature (ECT) sensor - The Mass Airflow (MAF) sensor - The Intake Air Temperature (IAT) sensor - The Vehicle Speed Sensor (VSS) - The transmission gear position or range information sensors - The engine Knock Sensors (KS) Page 9827 Abbreviations And Meanings - Part 13 Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 2534 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 2461 9. Install the distributor cap. 10. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to installation procedure 2 if malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the malfunction indicator lamp (MIL) is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. INSTALLATION PROCEDURE 2 Page 9531 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 8370 WA519F/12 - WA526F/72 Page 5736 C203 (Body Harness To IP Harness) Part 10 Locations Blower Motor Resistor: Locations Body Wiring To Blower Motor And Resistor (With RPO Code C42) Page 8381 WA810K/48 - WA812K/88 Page 5295 C433 (Body Harness To Defogger Grid Harness) Page 1645 8. Install the starter, if removed. 9. Lower the vehicle. Page 6069 Conversion English/Metric Part 2 Page 3805 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 793 Abbreviations And Meanings - Part 2 Specifications Power Steering Line/Hose: Specifications Power Steering Hose Clamps 18 inch lbs. Page 1257 Location View Page 6790 Air Bag Control Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Page 3843 Park Neutral Position (PNP) Switch Page 5132 Abbreviations And Meanings - Part 25 Page 1943 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 1646 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Refer to Engine Mounting Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the underbody shields, if equipped. 3. Remove the engine mount through-bolt and nut for the side being replaced. Notice: Refer to Engine Lifting Notice in Service Precautions. 4. Using a jack on the square tab (left side shown) at the rear of the engine block, raise the engine. In order to access the square tab on the right side remove the starter. 5. Raise the engine only enough to remove the engine mount. Page 7092 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 1233 Relay Block - Body Part 3 Locations Power Door Lock Actuator: Locations Front Passenger Door Shown, Driver Similar Page 1112 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON (R) II transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 4939 7. Remove the generator output (BAT) terminal retaining nut from the generator. INSTALLATION PROCEDURE 1. Connect the generator output (BAT) terminal wire. Ensure the insulating boot is covering the terminal nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the generator output (BAT) terminal nut to 17 N.m (12 lb ft). 2. Connect the generator electrical connector. Page 7090 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 9098 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 5785 C601 (Body Harness To Door Harness, RH Front) (W/ Power Locks/Windows) Part 2 Page 6054 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Frame Cushion or Insulator Replacement (Regular Cab) Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (Regular Cab) Frame Cushion or Insulator Replacement (Regular Cab) Removal Procedure Properly support the frame when you change the frame cushions. If only one cushion is changed, lower the entire side on which the cushion in placed in order to provide clearance for the cushion. 1. Raise the vehicle slightly on a hoist. Refer to Vehicle Lifting. 2. Place jack stands under the body on the side of the vehicle that the cushions will be placed. 3. Remove the frame cushion bolts. 4. Remove the retainer. 5. Remove the lower cushion. 6. Lower the hoist enough in order to leave the body supported by the jack stands. 7. Remove the upper cushion. 8. Remove the shims, if equipped. Installation Procedure 1. Install the shims, if equipped. 2. Install the upper cushion. Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 6148 6.3. Reverse the J 21474-6. 6.4. Tighten until the front bushing becomes free. Installation Procedure 1. Prior to removing or installing the bushing, place a wedge or spacer between the control arm bushing housing. This keeps the control arm bushing housing from bending while removing or installing the bushing. 2. Install the front bushing into the lower control arm. 3. Install the J 21474-4, the J 21474-5, and the J 21474-13. The lip is on the outside of the control arm. 4. Tighten until the front bushing seats fully into the lower control arm. Remove the tools. 5. Install the rear bushing into the lower control arm. 5.1. Install the J 22269-1, the J 21474-2, and the J 21474-13. The lip is on the outside of the control arm. 5.2. Tighten until the rear bushing seats fully into the lower control arm. Remove the tools. 6. Remove the lower control arm from the vise. 7. Install the lower control arm to the vehicle. Service and Repair Hood Shock / Support: Service and Repair Hood Hold-Open Rod Replacement Removal Procedure 1. Raise the hood. Support the hood with something other than the hood hold-open rod. 2. Remove the hood hold-open rod from the retainers. Pull the bottom of the rod toward you in order to release the rod from the bottom retainer. 3. Remove the retainers from the radiator support. Installation Procedure 1. Install the retainers to the radiator support. 2. Install the hood hold-open rod to the retainers. 3. Remove the temporary hood support. Locations Body Harness to Cowl Page 881 Step 8 Diagrams Remote Control Door Lock Receiver (RCDLR) Page 7626 Page 5372 C601 (Body Harness To Door Harness, RH Front) (W/ Power Locks/Windows) Part 3 Page 7623 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Specifications Fuel Gauge Sender: Specifications Page 2663 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 4525 10. Remove the outboard brake pad. 11. Inspect the disc brake caliper. 12. Inspect the caliper bolts and bushings for corrosion or damage, replace if damaged or corroded. Installation Procedure 1. Install the new anti/rattle retainers. Important: DO NOT reuse the old anti/rattle retainers. Use new anti/rattle retainers. 2. Install the outboard brake pad. Page 7260 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 6652 For vehicles repaired under warranty, use the table. Disclaimer Page 4690 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Master Cylinder Replacement Removal Procedure Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the parking brake and block the wheels. 2. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Plug the open brake pipe ends. 4. Remove the master cylinder nuts and bolts. 5. Remove the master cylinder from the vehicle. 6. Drain the master cylinder reservoir of all the brake fluid. Installation Procedure Specifications Spare Tire: Specifications Spare Tire Carrier Mounting Bolts (4WD Utility) 22 ft. lbs. Spare Tire Carrier to Body Side Inner Panel Mounting Bolts (2-Door Utility) 22 ft. lbs. Spare Tire Carrier to Frame Mounting Nuts (4-Door Utility) 27 ft. lbs. Spare Tire Carrier to Rear Crossmenber Mounting Bolts (4-Door Utility) 100 inch lbs. Spare Tire Carrier to Rear Crossmember Mounting Nuts (Pickup) 19 ft. lbs. Spare Tire to Spare Tire Carrier Mounting Nuts (4WD Utility) 74 ft. lbs. Page 6154 5. Install the catalytic converter hanger bracket to the transmission support mounting bolts, 4.3 L if necessary. Tighten the catalytic converter hanger bracket to the transmission support mounting bolts to 17 N.m (13 lb ft). 6. Install the catalytic converter hanger bracket to the transmission support mounting bolts, 2.2 L if necessary. Tighten the catalytic converter hanger bracket to the transmission support mounting bolts to 17 N.m (13 lb ft). 7. Install the transmission mount to the transmission support stud nut, 4.3 L pickup and utilities. Tighten the transmission mount to the transmission support stud nut to 45 N.m (33 lb ft). 8. Install the transmission mount to the transmission support stud nut, 2.2 L pickup. NV 1500 Shifter M/T: Service and Repair NV 1500 Control Lever and/or Boot Replacement Control Lever and/or Boot Replacement Removal Procedure 1. If equipped remove the 3 console nuts and the console. 2. Remove the shift lever from the shift tower. Do not remove the shift lever adjusting nut. 3. Pull back the carpet to access the screws. 4. Remove the screws securing the boot to the panel. Installation Procedure Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 4585 2. Install the adjusting screw assembly and the adjusting screw spring on the brake shoes. The coils of the adjusting screw spring must not touch the adjusting screw. 3. Install the brake shoes on the backing plate. 4. Install the strut spring on the park brake strut. 5. Install the park brake strut. 6. Install the actuator lever and the lever pivot. 7. Install the actuator lever return spring. 8. Install the hold down pins. 9. Install the hold down springs. Page 8057 3. Raise the frame slightly on the hoist. 4. Install the lower cushion. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the frame cushion bolts. Tighten the bolts to 70 N.m (52 lb ft). 6. Lower the hoist. Page 8360 Page 4142 4. On axles with a locking differential, place the axle shaft lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 5. Pull the shaft flange outward in order to seat the axle shaft lock into the differential side gear. 6. Install the pinion shaft. - Align the hole in the pinion shaft with the bolt hole in the differential case. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 7. Install the new pinion shaft lock bolt. Tighten the pinion shaft locking bolt to 25 Nm (18 lb ft). 8. Install the rear cover and the gasket. 9. Install the brake rotor, if equipped. 10. Install the brake caliper, if equipped. 11. Install the brake drum, if equipped. 12. Install the tire and wheel assembly. 13. Fill the rear axle. Use the proper fluid. 14. Lower the vehicle. Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Removal Procedure 1. Remove the rotor. 2. Remove the wheel stud. ^ Press the stud out using an arbor press. ^ Do not damage the wheel mounting surface on the wheel hub flange. Installation Procedure 1. Install the stud into the hole in the wheel hub. 1.1. Start the serrated stud into the hole in the wheel hub by tapping lightly with a hammer. 1.2. The stud must be square with the wheel hub before pressing on the arbor press. 2. Install the rotor. Page 9466 Page 4621 Page 4235 1. Remove the shift lever from the shift tower. Do not remove the shift lever adjusting nut. 2. Remove the screws securing the boot to the panel. 3. Remove the boot from the shift tower. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the boot over the shift tower and secure to the panel with the screws. ^ Tighten the screws to 2 Nm (18 inch lbs.). 2. Install the shift lever to the shift tower. If required, center the shift lever with the adjusting nut. ^ Tighten the adjusting nut to 48 Nm (35 ft. lbs.). Page 1760 37. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab. 38. Install the accelerator cable to the accelerator cable control bracket. 39. Install the air cleaner outlet duct. Page 8719 Heated Seat Control Module Driver/Front Passenger (Part of the Heated Seat Control Module) Driver/Front Passenger (Part of the Heated Seat Assembly) Page 8548 Seat Horizontal Motor - Front Passenger Page 2238 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Locations Neutral Safety Switch: Locations Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 708 Park Neutral Position (PNP) Switch Page 4169 The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Page 9709 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 1630 3. Observe the drive belt routing for the vehicles with air conditioning. 4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 5. Install the drive belt over the drive belt tensioner pulley. 6. Slowly release the tension on the drive belt tensioner arm. 7. Inspect for the drive belt being properly installed on the pulleys. Page 5276 C302 (Power Seat Harness, LH To Power Recliner Harness, LH) (w/ Power Seats, Memory) Page 572 Transfer Case (With RPO Code NP8) Harness Routing View Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Page 1806 ^ Crankshaft sprocket keyway for wear Installation Procedure 1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline. 2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. 3. Use the J 5590 in order to install the crankshaft sprocket. Important: Install the camshaft sprocket with the alignment mark at the 6 o'clock position. 4. Install the camshaft sprocket and the camshaft timing chain. Page 8289 Outside Rearview Mirror Switch Page 9410 Abbreviations And Meanings - Part 23 Disc Brake Component Specs Page 9392 Abbreviations And Meanings - Part 5 Page 1066 1. Install the power steering cooler hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering cooler hose to the power steering cooler. Tighten the power steering cooler hose to the power steering cooler clamp to 2 Nm (18 inch lbs.). 3. Connect the power steering cooler hose to the power steering pump. Tighten the power steering cooler hose to the power steering pump clamp to 2 Nm (18 inch lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the air cleaner assembly. 6. Bleed the power steering system. Page 8263 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. 3. Install the actuator to the top of the latch. IMPORTANT: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 4. Install the 2 screws (2) that retain the actuator (1) to the latch. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 0.75 N.m (6 lb in). Page 4893 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 5530 Abbreviations And Meanings - Part 9 Page 1408 When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations Page 9144 Abbreviations And Meanings - Part 22 Page 1110 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Page 7655 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 3066 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Page 2863 Page 9616 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 4271 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Page 7728 Body Control Module (BCM) C1 Part 2 Page 6899 Seat Belt Switch - LF Page 2240 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 7480 Speaker - LR (2-Door Utility) Page 777 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 4336 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 9412 Abbreviations And Meanings - Part 25 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 2700 Abbreviations And Meanings - Part 20 NV 1500 Transmission Speed Sensor: Service and Repair NV 1500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the vehicle speed sensor electrical connector. 3. Remove the vehicle speed sensor retaining bolt. 4. Remove the vehicle speed sensor. Installation Procedure 1. Install the new O-ring seal to the vehicle speed sensor. 2. Coat the new O-ring seal with a thin film of transmission fluid. 3. Install the vehicle speed sensor Notice: Refer to Fastener Notice in Service Precautions. 4. Install the vehicle speed sensor retaining bolt. ^ Tighten the vehicle speed sensor retaining bolt to 16 Nm (12 ft. lbs.). 5. Connect the vehicle speed sensor electrical connector. 6. Lower the vehicle. Page 9809 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 3287 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Gage Sensor ............................................................................................................................................................. 30 Nm (22 ft. lbs.) Engine Oil Pressure Gage Sensor Fitting - Plus Required Angle ............................................................................................................. 15 Nm (11 ft. lbs.) Page 8910 Cruise Control Module (CCM) Part 2 Page 2585 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 2332 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 5206 Application Table Part 5 Page 4313 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 3305 For vehicles repaired under warranty, use the table. Disclaimer Page 6815 Inflatable Restraint Front End Discriminating Sensor - Right OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 5019 Abbreviations And Meanings - Part 8 Page 9584 Page 8157 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Page 6276 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 1244 Application Table Part 3 Engine Controls - Lack of Power When Hot PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Lack of Power When Hot Bulletin No.: 05-06-04-077 Date: December 22, 2005 TECHNICAL Subject: Lack of Power (LU3 Engine) at High Ambient Temperatures Only (If Necessary, Reprogram PCM with New Service Calibration) Models: 2003-2005 Chevrolet Astro, Blazer, Express, S-10, Silverado 2003-2005 GMC Jimmy, Safari, Savana, Sierra, Sonoma with 4.3L Vortec(TM) V6 Engine (VIN X - RPO LU3) Condition Some customers may comment that the vehicle may exhibit a lack of power at high ambient temperatures. Cause Engineering has identified a concern with the PCM software. In high ambient temperatures, the engine control management system may falsely retard the timing, causing a noticeable loss of power. Correction Important: Before Reprogramming the PCM, verify the customer concern. Refer to SI Engine Controls and under Diagnostic Information and Procedures. Refer to Lack of Power, Sluggishness, or Sponginess for the cause of the low power condition at high ambient temperatures. If no trouble is found, then reprogram the PCM. Reprogram the PCM with the latest calibrations if the above concern is encountered. An updated PCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Refer to Service Programming System (SPS) using the appropriate Service Information (SI) procedures. The new PCM calibrations will be available to dealerships as part of TIS2000 incremental satellite update version 12.5, which was broadcast to dealers on 12/11/2005. For the dealerships that use CDs, the CD version will be 1.0 for 2006, which will be mailed 0111212006. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 9684 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 2448 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 3958 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 6429 Air Door Actuator / Motor: Service and Repair Defroster Actuator DEFROSTER ACTUATOR REPLACEMENT REMOVAL PROCEDURE The defroster actuator is located on the bottom left side of the HVAC module. 1. Remove the left side instrument panel sound insulator. 2. Remove the lower IP instrument panel sound insulator. 3. Disconnect the vacuum connector (3) from the defroster actuator (4). 4. Remove the actuator rod retaining clip (1). 5. Remove the actuator rod (2) from the defroster door lever (5). 6. Firmly pull on the defroster actuator in order to remove the actuator from the HVAC module. INSTALLATION PROCEDURE Page 5286 C402 (Body Harness To RH Tail Lamp Harness) (Export) Page 5156 Application Table Part 3 Page 7292 Abbreviations And Meanings - Part 18 Page 9780 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 7291 Abbreviations And Meanings - Part 17 Page 8966 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 1277 hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: - The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Page 9838 Abbreviations And Meanings - Part 24 Page 5174 Fuse Block - Underhood Connector C1 Part 5 Page 263 Seat Adjuster Switch - Front Passenger C2 (w/ 8-Way, w/o Memory) Page 9354 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 7252 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4735 2. Install the knee bolster trim panel. Page 7131 Abbreviations And Meanings - Part 24 Page 6526 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 5675 C210 (Body Harness To Redundant Steering Wheel Controls Harness) Page 804 Abbreviations And Meanings - Part 13 Page 5277 C303 (Power Seat Harness, RH To Power Recliner Harness, RH) (w/ Power Seats, Non-Memory) Page 8734 Outside Rearview Mirror Switch Page 5177 Fuse Block - Underhood Connector C1 Part 8 Page 5577 Location View Page 8547 Seat Horizontal Motor - Driver Page 7644 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 8957 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 5125 Abbreviations And Meanings - Part 18 Testing and Inspection Ignition Cable: Testing and Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 9357 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 3025 Steps 13-14 Page 9812 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6028 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 1726 10. Install a NEW oil pan drain plug seal (O-ring) onto the oil pan drain plug. 11. Install the oil pan drain plug into the oil pan. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). Important: The low oil level sensor is not reusable. Use a NEW low oil sensor. 12. Install the NEW engine oil level sensor (if applicable). Tighten the engine oil level sensor to 13 Nm (115 inch lbs.). Diagrams Windshield Washer Fluid Pump Page 6641 13. Remove the expansion (orifice) tube (2) from the evaporator (1). INSTALLATION PROCEDURE 1. Install the expansion (orifice) tube (2) to the evaporator (1). IMPORTANT:If replacing the evaporator core, add the refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information. 2. Install the evaporator core to the blower case section. 3. Assemble the evaporator case section to the blower case section. IMPORTANT:Ensure that the seal is in place between the 2 case sections. Page 6222 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9488 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 9405 Abbreviations And Meanings - Part 18 Seat Belt Replacement - Front Seat Belt: Service and Repair Seat Belt Replacement - Front REMOVAL PROCEDURE 1. Remove the bolt that retains the lower seat belt anchor plate to the vehicle. 2. Carefully pry open the upper seat belt anchor plate cover with a flat-bladed tool. Page 6997 Disclaimer Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 9585 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6820 4. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 5. Install the connector position assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 6. Install the off road skid plate, in equipped. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. Page 3304 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 9627 Abbreviations And Meanings - Part 8 Page 4096 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 763 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 8408 Memory Seat Module - Driver C2 Part 2 Page 5594 Fuse Block - Underhood Connector C2 Part 3 Page 9506 Abbreviations And Meanings - Part 2 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 9681 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 2851 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 9802 Equivalent - Decimal And Metric Part 2 Page 7650 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4884 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 1511 8. Remove the bolts and the balance shaft retainer. Important: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft. 9. Use a soft-faced hammer in order to remove the balance shaft from the engine block. 10. Clean and inspect the balance shaft. Installation Procedure Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft. 1. Apply clean engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent to the balance shaft front bearing. 2. Use the J 36996 and the J 8092 in order to install the balance shaft. Trim Panel Replacement - Knee Bolster Knee Diverter: Service and Repair Trim Panel Replacement - Knee Bolster TRIM PANEL REPLACEMENT - KNEE BOLSTER REMOVAL PROCEDURE 1. Set the park brake. 2. Block the wheels. 3. Remove the left-side instrument panel sound insulator. 4. Remove the lower instrument panel sound insulator. 5. Release the park brake release cable from the park brake lever. 6. Remove the screw that retains the courtesy lamp to the knee bolster. 7. Remove the screws that retain the knee bolster trim panel to the instrument panel. 8. Remove the knee bolster trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the knee bolster trim panel to the vehicle. 2. Install the screws that retain the knee bolster trim panel to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the TORX(r) screws to 9 N.m (80 lb in). - Tighten the hex head screws to 1.9 N.m (17 lb in). 1. Install the screw that retains the courtesy lamp to the knee bolster. 2. Install the park brake release cable to the park brake lever. 3. Install the lower instrument panel sound insulator. 4. Install the left-side instrument panel sound insulator. Page 9361 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 7639 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 5494 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 4990 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 2156 The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. NOT RUN SCC (NOT RUN SINCE CODE CLEAR): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 9735 Abbreviations And Meanings - Part 25 Page 1232 Relay Block - Body Part 2 Page 9742 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Procedures Head Rest: Procedures HEAD RESTRAINT REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE Depress the retainers located in the top of the seat back. Pull upward in order to remove the head restraint at the same time. INSTALLATION PROCEDURE Push the head restraint into the retainers at the top of the seat, ensuring that the head restraint locks into place. Page 5371 C601 (Body Harness To Door Harness, RH Front) (W/ Power Locks/Windows) Part 2 Page 5175 Fuse Block - Underhood Connector C1 Part 6 Service and Repair Exhaust Pipe: Service and Repair Exhaust Manifold Pipe Replacement Removal Procedure Caution: Refer to Protective Goggles and Gloves Caution in Service Precautions. Notice: Refer to General Vehicle Lifting and Jacking Notice in Service Precautions. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the catalytic converter. 3. Remove the exhaust manifold pipe to manifold flange bolts. 4. Remove the exhaust manifold pipe and seal from the vehicle. Installation Procedure 1. Install the exhaust manifold pipe and new seal to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust manifold pipe to manifold flange bolts. ^ Tighten the exhaust manifold pipe to manifold flange bolts to 30 Nm (22 ft. lbs.). 3. Install the catalytic converter. 4. Lower the vehicle. Page 9226 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the sensor and Distributor before removal. Do not allow debris to enter the engine. 1. Remove the distributor. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor using the J 41712. Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 4. Remove the engine oil pressure sensor fitting, if necessary. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the fitting and/or the engine oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. Page 2347 Disclaimer Page 1618 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Step 1 - 6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Specifications Power Steering Fluid: Specifications Fluid Type .......................... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent. Page 4740 6. Adjust the park brake cable. 7. Lower the vehicle. Refer to Vehicle Lifting. Page 3488 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Page 8987 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 9943 Rear Wiper/Washer And Endgate Window Release Switch Page 1494 6. Clean the components with cleaning solvent. 7. Dry the components with compressed air. 8. Inspect the valve rocker arm components for the following: ^ Valve rocker arm valve pushrod socket contact surface (1) The contact surface must be smooth with no scoring or excessive wear. ^ Valve rocker arm roller pivot for binding or damage (2) ^ Valve rocker arm valve stem contact surface (3) The contact surface should be smooth with no scoring or excessive wear. ^ Valve rocker arm bolt threads for damage (4) 9. Inspect the valve pushrods for the following: ^ Restriction of the oil passage (1) ^ Wear or scoring of the end contact surfaces (2) The end contact surfaces must be smooth with no scoring or excessive wear. ^ Shaft for bends (3) Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent. 10. Inspect the valve rocker support for excessive wear or damage. Page 3140 Steps 15-17 Page 5060 A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3921 5. Install the cable to the steering column bracket. 6. Install the retainer (2) that secures the cable to the steering column bracket. 7. Install the cable end (1) to the steering column ball stud. 8. Install the carpet and insulation to the drivers side floor area. 9. Install the door sill plate and the left hinge pillar trim panel. 10. Install the knee bolster and instrument panel trim. Page 5489 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 4974 Page 98 1. Slide the memory seat module into the bracket until the module is seated. 2. Install the memory seat module and bracket to the seat adjuster frame assembly with 2 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the memory seat module retaining screws to 3 N.m (26 lb in). 3. Install the memory seat module harness connectors. 4. Install the front seat to the vehicle. Page 9614 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 5450 Disclaimer Page 5043 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 3797 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 9101 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 7384 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 5099 Conversion English/Metric Part 2 Page 6608 Control Assembly: Description and Operation HVAC CONTROL MODULE The HVAC control assembly is a non-class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive and ignition 3 voltage circuits provide power to the control assembly. An integrated potentiometer controls air temperature door position. The integrated vacuum system controls the mode door position. The control assembly supports the features as in table. HVAC CONTROL ASSEMBLY The HVAC control assembly is a non-class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive and ignition 3 voltage circuits provide power to the control assembly. Two integrated potentiometers control air temperature door position and blower motor speed. The integrated vacuum system controls the mode door position. Page 8197 2. Remove the motor/actuator trim cover screw (2). 3. Lower the motor/actuator trim cover and remove the sunroof switch (4) from the cover (5). 4. Remove the 2 short screws (1, 2) from the sunroof panel window garnish molding. 5. Remove the 8 screw covers (3) from the lower sunroof panel window garnish molding. Page 6430 1. Install the defroster actuator. Ensure that the retaining tab locks into place. 2. Install the actuator rod (2) to the defroster door lever (5). 3. Install the actuator rod retaining clip (1). 4. Connect the vacuum connector (3) to the defroster actuator (4). 5. Install the lower IP instrument panel sound insulator. 6. Install the left side instrument panel sound insulator. Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2549 Page 1004 Disclaimer Page 5552 Registered And Non-Registered Trademarks - Part 4 Page 4600 3. Lubricate the adjuster screw. 4. Install the brake adjusting hardware. Fig. 8 Adjusting Brake Shoes To Brake Drum Inside Diameter 5. Adjust the rear brake and drum. 6. Install the brake drum Page 7884 6. Cut the tie straps securing the sunroof power feed wire to the body harness. IMPORTANT: Note the routing of the sunroof main feed wire on the body harness routed down the windshield pillar. 7. Cut the gray connector off the old main feed wire. 8. Tie the old wire onto the new main feed wire in order to aid in the location of the new wire. 9. Pull rearward, the LF center section of the door weather seal (1). 10. Located underneath the instrument panel, pull the new wire (2) up through and next to the left side of the instrument panel end cap (3). INSTALLATION PROCEDURE 1. Secure the sunroof wire to the windshield pillar body harness with new tie straps. 2. Position the new wire across the left front upper headliner area. 3. Connect the gray connector end of the wire (2) to the fused jumper at the lower fuse block. 4. Connect the electrical connector (1) to the sunroof switch connector. 5. Install the LF windshield pillar garnish molding. 6. Install the LF sunshade and retainer. 7. Reposition the LF door seal on the pinchweld flange. Page 2081 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Page 8750 Seat Adjuster Switch - Driver C1 (w/ 8-Way, w/o Memory) Part 1 Page 1779 Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail. 10. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. 10.1. Turn the J 35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. 10.2. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the crankshaft rear oil seal. 11. Remove the J 35621-B from the crankshaft. 12. Wipe off any excess engine oil with a clean rag. 13. Install the engine flywheel. 14. Install the transmission assembly. Page 2898 Knock Sensor (KS) Page 1016 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 842 Wiper Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Use a flat-bladed tool in order to pry the switch away from the instrument panel. 3. Disconnect the electrical connectors as necessary. INSTALLATION PROCEDURE 1. Connect the electrical connectors as necessary. 2. Install the switch to the instrument panel. 3. Connect the negative battery cable. Page 6473 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 7083 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 361 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 7645 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 4995 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 755 Page 9783 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 7436 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 4747 Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement Removal Procedure 1. Release the park brake, if applied. 2. Raise and the vehicle. Refer to Vehicle Lifting. 3. Remove the wheel and the tire. 4. Remove the park brake cable from the park brake lever. Important: In the following service procedure, the brake caliper and mounting ' bracket does not have to be separated. Relocate the brake caliper and bracket to the side and secure. 5. Remove the rear brake caliper and bracket assembly. Locations Electronic Components Page 2915 Heated Oxygen Sensor (HO2S), Bank 2 Sensor 1 Page 6221 The smearing of the metal is due to slippage. Slippage can be caused by the following factors: ^ Poor fits ^ Lubrication ^ Overheating ^ Overloads ^ Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Page 5500 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 5369 C501 (Body Harness To LH Front Door Harness) (4-Door) Part 2 Page 9364 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Cooling System - Rubbing/Scraping Noise on Turns Fan Shroud: All Technical Service Bulletins Cooling System - Rubbing/Scraping Noise on Turns Bulletin No.: 03-06-02-006 Date: July 30, 2003 TECHNICAL Subject: Rubbing/Scraping Noise During Turns (Reposition Cooling Fan Shroud) Models: 2003 Chevrolet Blazer, S-10 2003 GMC Jimmy, Sonoma with 4.3L V6 Engine (VIN X RPO LU3) Condition Some customers may comment on a rubbing/scraping noise during turns, more commonly left turns. Cause This sound resembles a tire rubbing against the inner tender, but may actually be the engine cooling fan contacting the fan shroud. Correction 1. Loosen the three upper cooling fan shroud bolts. 2. Reposition the shroud so there is a equal amount of clearance all the way around the fan and the shroud. 3. Tighten the upper cooling tan shroud bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8550 Seat Lumbar Motor - Front Passenger Page 4891 Conversion English/Metric Part 1 Locations Steering Wheel Control Switches Page 732 2. Install the following parts: 2.1. The O-ring on the vehicle speed sensor assembly. 2.2. The vehicle speed sensor assembly. 2.3. Tighten Tighten the bolt to 16 Nm (12 ft. lbs.). 3. Install the electrical connector to the vehicle speed sensor. 4. Lower the vehicle. Page 5715 C106 (Forward Lamp Harness To Body Harness) Part 1 Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables by loosening the nut at the equalizer. 5. Remove the rear park brake cable from the park brake actuator lever. 6. Remove the park brake cable from the mounting bracket by depressing the locking tabs. 7. Remove the rotor. 8. Remove the axle shaft. 9. Remove the park brake shoe. 10. Remove the backing plate bolts. 11. Remove the park brake actuator lever housing from the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Perform the following procedure before installing the backing plate bolts. 2.1. Remove all traces of the original adhesive patch. 2.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 2.3. Apply Threadlocker GM P/N 12345493, Red LOCTITE #272, or for Canada use P/N 10953488 to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the backing plate bolts. Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. 6. Adjust the park brake shoe. 7. Install the rotor. 8. Install the park brake cable to the mounting bracket until the locking tabs snap into place. 9. Install the rear park brake cable to the park brake actuator lever. 10. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 3.5 Nm (31 inch lbs.). 11. Install the tire and wheel assembly. 12. Remove the safety stands. 13. Lower vehicle. 14. Adjust park brake cable. Page 3975 1. Install a new retaining ring into the quick connect fitting using the following procedure: 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. Page 1237 Relay Block - Body Part 7 Service and Repair Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Removal Procedure 1. Peel back the weatherstrip tape in order to reveal the molding screws. 2. Remove the fasteners. 3. Remove the reveal molding from the windshield pillar. Installation Procedure 1. Install the reveal molding to the windshield pillar. 2. Install the fasteners. 3. Install the new weatherstrip tape (if required). Page 5741 C209 (Dome Harness To Body Harness) Part 3 Page 4522 Installation Procedure Important: Before installing new brake pads, clean the outside surface of the caliper boot with denatured alcohol. 1. Install the outboard lining. 2. Install the retainer spring on the inboard brake lining. 3. Install inboard lining in the caliper. Notice: Refer to Installing Hoses without Twists or Bends Notice in Service Precautions. 4. Install the caliper. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Refer to Vehicle Lifting. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the brake master cylinder to the proper level. 11. Burnish the new brake pads. Page 2132 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module (BCM) C3 Part 1 Page 6500 Abbreviations And Meanings - Part 1 Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement (Utility) Removal Procedure 1. Remove the body side stationary window (2-Door only). 2. Remove the molding from the quarter panel rear window (4-Door only). 3. Remove the pressure relief ventilation valve using a flat-bladed tool in order to release the retainers. Installation Procedure 1. Install the pressure relief ventilation valve assembly pressing into place until firmly seated. Page 4629 3. Install the brake hose bolt and washers. Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 4. Fill the brake master cylinder to the proper level. 5. Bleed the brake calipers. 6. Install the tire and wheel assembly, 7. Lower the vehicle. Refer to Vehicle Lifting. Page 8178 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the sunshade retainer and the sunshade retainer screws. Tighten the screws to 1.1 N.m (10 lb in). 3. Connect the electrical connections, if equipped. 4. Install the screws that retains the sunshade to the roof. Tighten the screws to 1.1 N.m (10 lb in). Page 1069 Power Steering Line/Hose: Service and Repair Power Steering Return Hose Replacement Power Steering Return Hose Replacement Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the air cleaner assembly. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering return hose from the power steering pump (for vehicles without a power steering cooler). 4. Disconnect the power steering gear return hose from the power steering cooler, if equipped. 5. Disconnect the wiring harness clip from the power steering return hose at the power steering gear. 6. Disconnect the power steering gear return hose from the power steering gear. 7. Remove the power steering gear return hose from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 379-427 kPa (55-62 psi) Page 6537 Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Remove the blower motor relay (1) from the retaining bracket. 3. Disconnect the electrical connector. 4. Remove the blower motor relay. INSTALLATION PROCEDURE 1. Install the blower motor relay. 2. Connect the electrical connector. 3. Install the blower motor relay (1) to the retaining bracket. 4. Connect the negative battery cable. Page 9635 Abbreviations And Meanings - Part 16 Page 8328 WA423G/79 - WA519F/12 Page 2403 Steps 18-23 Page 9689 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 3243 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Shift Cable: Customer Interest A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 359 Engine, LR Console Replacement - Front Floor (Full Length (Auto Trans) Console: Service and Repair Console Replacement - Front Floor (Full Length (Auto Trans) CONSOLE REPLACEMENT - FRONT FLOOR (FULL LENGTH (AUTO TRANS)) REMOVAL PROCEDURE 1. Remove the shift handle retaining clip at the front of the handle. 2. Remove the shift handle from the shift lever. 3. Open the console lid. 4. Remove the console compartment inserts. Page 2491 Intake Air Temperature (IAT) Sensor 1. Install the IAT sensor by gently pushing the sensor into the air cleaner outlet duct until seated. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Page 770 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Procedures Seat Cushion: Procedures Seat Cushion Trim Cover and Pad Replacement (Bench) SEAT CUSHION TRIM COVER AND PAD REPLACEMENT (BENCH) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the seat back release lever, if equipped. 3. Remove the seat back. 4. Separate the J-strips from the seat bottom frame. 5. Remove the manual lumbar knob lever, if equipped. 6. Remove the seat bottom cover. 7. Remove the seat bottom pad. INSTALLATION PROCEDURE 1. Install the seat bottom pad to the seat bottom. 2. Install the seat bottom cover over the pad. 3. Engage the J-strips to the seat bottom frame. 4. Install the seat back. 5. Install the seat back release lever, if equipped. 6. Install the manual lumbar knob lever, if equipped. 7. Install the seat to the vehicle. Seat Cushion Trim Cover and Pad Replacement (Bucket) Page 3089 Central Sequential Fuel Injection (Central SF1) Part 2 Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 8581 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. INSTALLATION PROCEDURE Page 5555 Accessory Power Outlet - Right Page 7299 Abbreviations And Meanings - Part 25 Page 7226 Page 5767 C402 (Body Harness To RH Tail Lamp Harness) (Export) Locations Relay Block - Body Relays, Except Envoy Page 2852 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 4926 Abbreviations And Meanings - Part 26 Page 7756 6. Install the front wheel opening flare extension, if equipped. 7. Install the radiator air intake baffle. 8. Install the grille. Remote Cassette Player Replacement Tape Player: Service and Repair Remote Cassette Player Replacement REMOTE CASSETTE PLAYER REPLACEMENT REMOVAL PROCEDURE 1. Remove the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the remote cassette player tray by prying gently with a flat-bladed tool. 3. Remove the remote cassette player by gently pulling the unit outward from the console. 4. Remove the electrical connector. INSTALLATION PROCEDURE 1. Install the electrical connector. 2. Install the remote cassette player to the console, by sliding the unit into place between the retaining tabs. 3. Install the remote cassette player tray, ensuring the unit locks into place. 4. Install the negative battery cable. Page 9723 Abbreviations And Meanings - Part 13 Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Page 6109 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 7581 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Locations Seat Harness Routing (8-Way w/o Memory) Page 5267 C217 (Body Harness To IP Harness) Page 4094 11. Using J28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 6040 Page 8613 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 6086 Abbreviations And Meanings - Part 9 Page 5629 1. Install the ground strap. 2. Install the ground strap bolt to the cowl. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ground strap to cowl bolt to 17 N.m (12 lb ft). 3. Raise the vehicle. 4. Install the ground strap bolt to the engine. Tighten Tighten the ground strap bolt to 50 N.m (37 lb ft). 5. Lower the vehicle. Page 1346 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 4715 Parking Brake Cable: Service and Repair Park Brake Cable Mounting Bracket Replacement Park Brake Cable Mounting Bracket Replacement Removal Procedure 1. Release the parking brake, if applied. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the park brake equalizer. 4. Using the J37043 (1), collapse the locking tabs on the park brake cable. 5. Remove the park brake cable from the mounting bracket. 6. Remove the cable mounting bolts for the mounting bracket. Wheel Alignment Specifications Wheel Alignment Specifications Page 9373 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 8671 Conversion English/Metric Part 1 Page 2165 Engine Generator And Starter Page 1712 1. Install NEW seals on both ends of the remote oil filter inlet and outlet hoses. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the remote oil filter inlet and outlet hoses and the bolt to the oil filter pipe adapter. Tighten the remote oil filter inlet and outlet hose to remote oil filter pipe adapter bolt to 35 Nm (26 ft. lbs.). 3. Install the remote oil filter inlet and outlet hoses to the remote oil filter adapter. Tighten the remote oil filter inlet and outlet hose to the remote oil filter adapter bolt to 35 Nm (26 ft. lbs.). Page 9738 Registered And Non-Registered Trademarks - Part 1 Page 4872 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 1214 Fuse Block - Underhood Connector C1 Part 5 Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug ............................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Page 5362 C433 (Body Harness To Defogger Grid Harness) Page 8268 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws (2) that retain the actuator (1) to the latch. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the latch to the door. 6. Install the water deflector. 7. Install the door trim panel. Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws (2) that retain the lock actuator (1) to the latch. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. Installation Procedure Page 8702 Abbreviations And Meanings - Part 22 Page 2268 4. Install the distributor. 5. Connect the negative battery cable. Page 3992 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 NV 1500 Vehicle Speed Sensor Page 1396 Wheels: Testing and Inspection Wheel Mounting Surface Check Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 203-229 mm (8-9 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components Page 5650 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 1 Page 1826 Tighten the bolts to 12 N.m (106 lb in). Parts Information Warranty Information Page 3286 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 9393 Abbreviations And Meanings - Part 6 Page 976 accessory component bracket. Page 8195 3. Remove the front side door lock pillar garnish molding from the vehicle. Feed the seat belt through the garnish molding. INSTALLATION PROCEDURE 1. Install the front side door lock pillar garnish molding to the vehicle. Feed the seat belt through the garnish molding. 2. Install the upper and the lower front seat belt anchor bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 70 N.m (52 lb ft). 3. Install the front and the rear door sill trim plates. Garnish Molding Replacement - Windshield Pillar GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE Page 3575 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 9570 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5625 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 3088 Fuel Injector: Diagrams Central Sequential Fuel Injection (Central SF1) Part 1 Page 1621 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Drive Belt Rumbling Diagnosis Step 1 - 8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Page 398 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Page 5784 C501 (Body Harness To LH Front Door Harness) (4-Door) Part 3 C601 (Body Harness To Door Harness, RH Front) (W/ Power Locks/Windows) Part 1 Page 3620 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support retaining bolts. Page 9338 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 3103 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS - Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help isolate an intermittent condition. - Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics - For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Page 1213 Fuse Block - Underhood Connector C1 Part 4 Page 5285 Multiple Junction Connector: Diagrams C401 - C433 C402 (Body Harness To RH Tail Lamp Harness) (Domestic) Page 1445 Wheel Nut Torque Sequence Page 8253 Door Lock Cylinder Switch - Driver (Utility W/ Content Theft) Page 1588 Valve Guide: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 5892-D Valve Spring Compressor - J 42073 Valve Stem Seal Installer Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the required valve rocker arms. 3. Remove the required spark plugs. 4. Install the J 22794 into the spark plug hole. 5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 6. Remove a bolt from a valve rocker arm. 7. Install a flat washer on the bolt. 8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 9. Use the J 5892-D in order to compress the valve spring. 9.1. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Page 4214 4. Install the front bearing retainer and the 6 bolts to the transmission. ^ Tighten the 6 bearing retainer bolts to 14 Nm (10 ft. lbs.). 5. Install the clutch actuator and the bolts. ^ Tighten the clutch actuator bolts to 8 Nm (71 inch lbs.). 6. Install the transmission. Transmission Housing Oil Seal Replacement - Rear Transmission Housing Oil Seal Replacement - Rear ^ Tools Required J 23129 Universal Seal Remover - J 6125-1B Slide hammer - J 36503 Seal Installer Removal Procedure Page 2625 container regarding cleaner usage. - DO NOT use a cleaner containing an extremely powerful solvent such as methl ethyl ketone. - Shiny spots on the pintle and seat do not represent a bent or misaligned pintle shaft. - If heavy deposits are present in the air passage, remove the throttle body for a complete cleaning. 2. Replace the IAC valve O-ring. IMPORTANT: DO NOT reuse the original O-ring. INSTALLATION PROCEDURE 1. On a new IAC valve, measure the distance between the IAC valve pintle and mounting flange. Use finger pressure to slowly retract the pintle if the distance is more than 28 mm (1-1/8 in). IMPORTANT: Use an identical part when installing a new idle air control (IAC) valve. The IAC valve pintle shape and dimensions are designed for specific applications. 2. Lubricate the IAC valve O-ring with clean engine oil. 3. Align the flange holes with the mounting holes on the throttle body assembly. 4. Insert the IAC valve through the O-ring into the throttle body assembly. 5. Install the IAC valve mounting screws. Page 9137 Abbreviations And Meanings - Part 15 Page 7367 Page 5547 Abbreviations And Meanings - Part 26 Page 817 Abbreviations And Meanings - Part 26 Page 7234 Page 3477 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 9596 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 6682 INSTALLATION PROCEDURE 1. Insert the J 44551 -6 sizing tool (1) into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the suction hose. 3. Install the J 44551 -3 mandrel (1) to J 44551 -5. 4. Install the J 44551 -5 suction screen installation tool (3) over the end of the suction hose and the suction screen (2). 5. Tighten the forcing screw of J 44551 -5. The suction screen is fully installed when the screen is flush with the end of the suction hose. IMPORTANT:Correct placement of J 44551 -5 is critical. 6. Remove the J 44551 -5 suction screen tool from the suction hose. Page 9448 For vehicles repaired under warranty, use the table. Disclaimer Page 5756 C301 (Dome Harness To Overhead Console) (w/o GDO) Page 5900 Alignment: Description and Operation Thrust Angle Description Thrust Angles Description The front wheels aim or steer the vehicles. The real wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Page 1501 6. Clean the components with cleaning solvent. 7. Dry the components with compressed air. 8. Inspect the valve rocker arm components for the following: ^ Valve rocker arm valve pushrod socket contact surface (1) The contact surface must be smooth with no scoring or excessive wear. ^ Valve rocker arm roller pivot for binding or damage (2) ^ Valve rocker arm valve stem contact surface (3) The contact surface should be smooth with no scoring or excessive wear. ^ Valve rocker arm bolt threads for damage (4) 9. Inspect the valve pushrods for the following: ^ Restriction of the oil passage (1) ^ Wear or scoring of the end contact surfaces (2) The end contact surfaces must be smooth with no scoring or excessive wear. ^ Shaft for bends (3) Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent. 10. Inspect the valve rocker support for excessive wear or damage. Page 6135 7. Remove the lower control arm out of the opening in the splash shield. Use a putty knife or a similar tool in order to guide the control arm past the splash shield. 8. Remove the lower ball joint from the lower control arm using J 9519-D. 9. Inspect the tapered hole in the steering knuckle and remove any dirt. If the tapered hole is out of round, deformed, or damaged, replace the steering knuckle. Installation Procedure 1. Install a new ball joint into the lower control arm. 1.1. Press in the ball joint using J 9519-D. The ball joint will bottom on the control arm. 1.2. Locate the grease fitting facing inboard. 2. Install the ball joint stud into the steering knuckle. Page 9533 Registered And Non-Registered Trademarks - Part 2 Page 2386 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 743 Page 1709 Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. 1. Install a new retaining ring into each quick connector fitting. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Page 5064 Diagrams Power Seat Control Module: Diagrams Memory Seat Module - Driver C1 Part 1 Page 4643 3. Remove the brake hose to brake caliper bolt. Important: The gaskets may be stuck to the brake caliper and/or the brake hose end. 4. Discard the metal gaskets. 5. Plug the opening in the front brake hose with a rubber plug in order to prevent brake fluid loss and contamination. 6. Remove the caliper guide pin bolts. 7. Remove the caliper from the caliper anchor bracket. Installation Procedure NV 1500 Vehicle Speed Sensor Page 6541 Body Wiring To Blower Motor And Resistor (With RPO Code RPO C60) Page 4224 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the electrical connector from the vehicle speed sensor. 3. Remove the following parts: ^ The vehicle speed sensor ^ The O-ring seal Installation Procedure 1. Coat a new O-ring seal with a thin film of transmission oil. Notice: Refer to Fastener Notice in Service Precautions. Page 5810 Location View Page 6296 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 7871 REMOVAL PROCEDURE 1. Remove the window weatherstrip. 2. Remove the door handle bezel. 3. Remove the window regulator handle, if equipped. 4. Remove the power window switch, if equipped. 5. Remove the trim panel screws from the armrest. Carefully pry off the cover using a flat-bladed tool. 6. Use the J 38778 in order to release the door trim panel retainers. 7. Remove the door trim panel from the door. INSTALLATION PROCEDURE 1. Install the door trim panel to the door. 2. Install the trim panel armrest screws to the armrest. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Position the cover and snap the cover into place. 4. Install the power window switch, if equipped. 5. Install the window regulator handle, if equipped. 6. Install the inside door handle bezel. 7. Install the window weatherstrip. Page 7667 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 9516 Abbreviations And Meanings - Part 12 Page 5542 Abbreviations And Meanings - Part 21 Page 5887 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 760 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 2374 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 9074 Page 1411 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling Page 8570 Seat Adjuster Switch - Front Passenger C1 (w/ 8-Way, w/o Memory) Part 2 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 1960 1. Install the fan blade to the fan clutch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan blade mounting bolts. Tighten the bolts to 33 Nm (24 ft. lbs.). 3. Install the fan clutch assembly using the J 46406. Tighten the fan clutch to 56 Nm (40 ft. lbs.). 4. Install the upper fan shroud. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 1276 Vehicle Lifting: Service and Repair Vehicle Lifting Points VEHICLE LIFTING POINTS The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and Page 3914 Disclaimer Page 8152 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: Page 9135 Abbreviations And Meanings - Part 13 Page 3093 Steps 1-4 Page 820 Registered And Non-Registered Trademarks - Part 2 Page 3470 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Install the J 34730-1A to the fuel pressure service connection. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Turn ON the ignition. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 4. Command the fuel pump ON with a scan tool. 5. Close the bleed valve on the fuel pressure gage. 6. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. Page 4978 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8119 5. Open the storage compartment cover. 6. Remove the storage compartment. 7. Remove the nuts that retain the console to the vehicle. 8. Disconnect the electrical connector, if equipped. 9. Remove the console from the vehicle. Installation Procedure 1. Install the console to the vehicle. 2. Connect the electrical connector, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts that retain the console to the vehicle. Tighten the nuts to 10 N.m (88 lb in). 4. Install the storage compartment to the vehicle. 5. Install the trim plate to the console. 6. Install the screws that retain the trim plate to the console. Tighten the nuts to 1.9 N.m (17 lb in). Page 5094 Equivalent - Decimal And Metric Part 1 Page 3846 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 8636 Page 2219 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 7070 Page 3247 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 563 Park Neutral Position (PNP) Switch Page 2819 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Page 4399 Page 4875 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 4302 Page 1043 7. Place the heater inlet hose in the retaining clip above the right side valve cover. 8. Close the retaining clip. Ensure that the clip locks. 9. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 9482 HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 6870 1. Install the seat belt retractor assembly to the vehicle. 2. Install the bolt that retains the seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt retractor assembly bolt to 70 N.m (52 lb ft). 3. Guide the seat belt through the opening in the body side trim cover. 4. Install the body side trim panel. 5. Install the seat belt opening trim cover by firmly pressing the cover into place. Page 8638 Page 5611 Relay Block - Body Part 7 Page 4805 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 4729 6. Using the J37043 (1), collapse the locking tabs on the park brake cable. 7. Remove the park brake cable from the equalizer. Installation Procedure Important: When installing the park brake cable in the equalizer, ensure that the locking tabs on the park brake cable are properly seated against the equalizer. 1. Install the park brake cable in the equalizer. Page 3368 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 7138 Registered And Non-Registered Trademarks - Part 4 Page 9175 Disclaimer Page 2621 Steps 10-11 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 9845 Registered And Non-Registered Trademarks - Part 4 Page 6327 Disclaimer Cooling System - Rubbing/Scraping Noise on Turns Fan Blade: All Technical Service Bulletins Cooling System - Rubbing/Scraping Noise on Turns Bulletin No.: 03-06-02-006 Date: July 30, 2003 TECHNICAL Subject: Rubbing/Scraping Noise During Turns (Reposition Cooling Fan Shroud) Models: 2003 Chevrolet Blazer, S-10 2003 GMC Jimmy, Sonoma with 4.3L V6 Engine (VIN X RPO LU3) Condition Some customers may comment on a rubbing/scraping noise during turns, more commonly left turns. Cause This sound resembles a tire rubbing against the inner tender, but may actually be the engine cooling fan contacting the fan shroud. Correction 1. Loosen the three upper cooling fan shroud bolts. 2. Reposition the shroud so there is a equal amount of clearance all the way around the fan and the shroud. 3. Tighten the upper cooling tan shroud bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3831 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ Me X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. Page 9455 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5326 C209 (Dome Harness To Body Harness) Part 2 Page 3221 12.5. Verify the throttle position has gone from 0-100 percent and back to 0 percent. IMPORTANT: The accelerator pedal should operate freely without binding between closed and wide open throttle (WOT). Page 6914 4. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 5. Install the connector position assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 6. Install the off road skid plate, in equipped. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. Page 4365 Transmission Position Switch/Sensor: Diagrams ParklNeutral Position (PNP) Switch C1 Park Neutral Position (PNP) Switch C2 Locations Floor Pedals Page 8140 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Page 9837 Abbreviations And Meanings - Part 23 Page 129 Body Wiring To Blower Motor And Resistor (With RPO Code RPO C60) Page 1873 3. Tighten the air cleaner cover wingnuts. Page 4748 6. Remove the rear brake rotor. 7. Using denatured alcohol, clean the park brake shoe assembly. 8. Using non-lubricated, filtered compressed air, dry the park brake shoe assembly. 9. Slide the park brake shoe (2) down until it is disengaged from the hold down spring (3). 10. Lift the shoe (2) away from the backing plate and slide the shoe up, off of the actuation mechanism (1). 11. Remove the shoe (2) over the axle flange and from the vehicle. 12. Turn the adjustment screw to the fully home position in the notched adjustment nut, then back it off 1/4 turn. 13. Align the slots in both the adjusting screw and tappet to be parallel with the backing plate face. 14. Using denatured alcohol, clean the rear backing plate of dirt and foreign materials. 15. Using non-lubricated, filtered air, dry the backing plate. Installation Procedure 1. Install a new park brake shoe (2) over the axle flange. 2. Position the shoe (2) on the actuation mechanism. 3. Holding the lower end of the shoe (2) away from the backing plate, slide the shoe down, over the top of the hold down spring (3). 4. Place the lower end of the shoe (2) against the backing plate. 5. Slide the shoe (2) up and under the hold down spring (3). Important: The shoe must be central on the backing plate and with both tips located in the slots of the actuation mechanism (1). 6. Inspect the position of the shoe assembly. 7. Manually check the park brake for proper operation by moving the park brake actuator lever and observing the movement of the actuation mechanism. Page 6642 4. Install the 6 retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to.................1.9 N.m (17 lb in). 5. Install the evaporator and blower module to the vehicle. IMPORTANT:Ensure that the evaporator and blower module to the cowl seal is in place. 6. Install the evaporator and blower module mounting fasteners. IMPORTANT:Install the evaporator and blower module heat shield mounting bracket with the evaporator and blower module mounting nuts. Tighten Tighten the fasteners to.....................4.5 N.m (40 lb in). 7. Install the evaporator and blower module heat shield. 8. Install the evaporator and blower module heat shield mounting screws. Tighten Tighten the screws to.......................2.2 N.m (19 lb in). 9. Install the evaporator tube. 10. Install the accumulator. 11. Install the blower motor resistor. 12. Install the right fender. 13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the components using the J 39400-A. Page 656 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Page 7863 4. Remove the bolts retaining the lower latch to the door. 5. Remove the lower latch bolt. Installation Procedure Page 3496 Page 9638 Abbreviations And Meanings - Part 19 Page 1720 3. Install the NEW oil pan gasket into the groove in the oil pan. Important: The oil pan alignment must always be flush or forward no more than 0.3 mm (0.011 inch) from the rear face of the engine block. 4. Install the oil pan onto the engine block. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing. 5. Slide the oil pan back against a suitable straight edge. 6. Install the oil pan bolts and nuts, but do not tighten. 7. Measure the pan-to-transmission housing clearance using a feeler gage and a straight edge. Use a feeler gage to check the clearance between the oil pan-to-transmission housing measurement points. If the clearance exceeds 0.3 mm (0.011 inch) at any of the 3 oil pan-to-transmission housing measurement points (1), then repeat the step until the oil pan-to-transmission housing clearance is within the specification. The oil pan must always be forward of the rear face of the engine block. Notice: Refer to Fastener Notice in Service Precautions. Page 6371 The smearing of the metal is due to slippage. Slippage can be caused by the following factors: ^ Poor fits ^ Lubrication ^ Overheating ^ Overloads ^ Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Page 8569 Seat Adjuster Switch - Driver C1 (w/ 8-Way, w/o Memory) Part 2 Seat Adjuster Switch - Front Passenger C1 (w/ 8-Way, w/o Memory) Part 1 Page 2017 Disclaimer Page 5571 Application Table Part 4 A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Locations Low Pressure Sensor / Switch: Locations A/C Accumulator Page 864 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angle Description Thrust Angles Description The front wheels aim or steer the vehicles. The real wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the Page 8199 5. Install the 8 sunroof panel window garnish molding screw covers. 6. Position the sunroof switch (4) to the motor/actuator trim cover (5). 7. Locate switch to cover in order to secure. 8. Position motor/actuator trim cover to the sunroof panel window garnish molding. 9. Install the motor/actuator trim cover screw (2). Tighten Tighten the screw to 1.5 N.m (13 lb in). 10. Install the motor/actuator service cover. Garnish Molding Replacement - Rear Upper Garnish Molding Replacement - Rear Upper Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Page 7695 Abbreviations And Meanings - Part 23 Page 869 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Important: Before you adjust caster and camber angles, raise and release the front bumper. Do this twice in order to allow the vehicle to return to a normal height. 1. Adjust the caster and the camber by inserting shims between the upper control arm shaft and the frame bracket. Add shims or subtract shims or transfer shims in order to change the readings. 2. In order to adjust the caster and the camber, loosen the upper control arm shaft-to-frame nuts (1). Add shims or remove shims (2) as required. Tighten the nuts. Check the toe after you change the caster and the camber. 3. Caster-Transfer the shims from front to rear or from rear to front. The transfer of one shim from the rear bolt to the front bolt decreases positive caster. 4. Camber-Change the shims at the front and the rear of the cross shaft. Add an equal number of shims at the front and the rear of the cross shaft. This decreases positive camber. 5. A normal shim pack will leave at least two threads of the bolt exposed beyond the nut (1). The difference between the front shim pack and the rear shim pack must not exceed 10 mm (0.40 inch). If you cannot meet these requirements, check for damage to the control arms and to related parts. 6. Tighten the nut on the thinner shim pack first. This improves the shaft-to-frame clamping force. This also improves torque retention. Page 5959 7. Remove the hood latch support mounting bolts. 8. Move the hood latch support forward. 9. Remove the power steering cooler retaining bolts. 10. Remove the power steering cooler from the radiator support. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. 1. Install the power steering cooler to the radiator core support. Notice: Refer to Fastener Notice in Service Precautions. Procedures Sun Visor: Procedures SUNSHADE REPLACEMENT REMOVAL PROCEDURE 1. Remove the screws that retain the sunshade to the roof. 2. Disconnect the electrical connections, if equipped. 3. Remove the screw that retains the sunshade retainer to the roof. 4. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 4940 3. Install the generator to the generator mounting bracket. 4. Install the generator mounting bolts. Tighten Tighten the generator mounting bolts to 50 N.m (37 lb ft). 5. Install the heater hose bracket bolt to the generator. Tighten Tighten the heater hose bracket to the generator bolt to 25 N.m (18 lb ft). 6. Install the drive belt. 7. Connect the negative battery cable. Page 7325 Disclaimer Page 2371 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Page 6277 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 3578 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 811 Abbreviations And Meanings - Part 20 Page 1839 Timing Cover: Service and Repair Engine Front Cover Replacement Removal Procedure 1. Remove the engine oil pan. 2. Remove the crankshaft balancer. 3. Remove the water pump. 4. Remove the Crankshaft Position (CKP) sensor. 5. Remove the crankshaft position sensor seal (O-ring). 6. Discard the crankshaft position sensor seal (O-ring). 7. Remove the engine front cover bolts. Important: After the composite engine front cover is removed do not reinstall the engine front cover. Always install a NEW engine front cover. 8. Remove the engine front cover. 9. Discard the engine front cover. 10. Clean all sealing surfaces. Installation Procedure Important: Once the composite engine front cover is removed DO NOT reinstall the engine front cover. Always install a NEW engine front cover. Page 5205 Application Table Part 4 Power Mirror Switch Replacement Power Mirror Switch: Service and Repair Power Mirror Switch Replacement POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Engine Controls - Excessive Fuel Gauge Fluctuation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Excessive Fuel Gauge Fluctuation Bulletin No.: 03-08-49-014A Date: October 02, 2003 TECHNICAL Subject: Fuel Gauge Fluctuates Between E and 1/4 Tank, Goes From 1/4 to Empty Too Quickly, Excessive Empty Fuel Reserve (Reprogram PCM) Models: 2001-2003 Chevrolet Blazer 2001 GMC Envoy 2001-2003 GMC Jimmy Supercede: This bulletin is being revised to add condition information. Please discard Corporate Bulletin Number 03-08-49-014 (Section 08 - Body and Accessories). This bulletin contains three different conditions depending on the model year of the vehicle involved. Condition # 1 (2001 4-Door Only) Some customers may comment that the fuel gauge goes from 1/4 to empty too quickly. Condition # 2 (2002 4-Door Only) Some customers may comment about excessive empty fuel reserve. Condition # 3 (2003 2-Door and 4-Door) Some customers may comment that the fuel gauge fluctuates between E and 1/4 tank. Correction Important: In order to select the correct calibration on some vehicles, you must first identify the cluster part number. This can be done using the Tech 2. DO NOT REMOVE THE CLUSTER. A new service calibration has been released to correct these conditions. Reprogram the PCM using the new service calibration, which was available from Techline starting August 25, 2003 on the TIS2000 version 9.0 or later. This calibration is an electronic calibration and is not available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 7551 For vehicles repaired under warranty use, the table. Disclaimer Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 7580 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 8401 Paint: Service and Repair Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Service Precautions. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D-99 identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel.) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products Page 463 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 8393 WA882K/90 - WA900J/59 Page 1589 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use J 38606 when J 5892-D will not fit. 11. Remove the valve keys (1) 12. Carefully release the valve spring tension 13. Remove the J 5892-D or the J 38606. 14. Remove the valve spring cap (2) and valve spring (3). 15. Remove the valve stem oil seal (4). Installation Procedure Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement GARAGE DOOR OPENER REPLACEMENT The overhead console (4) on some models provides a location for installing a garage door opener transmitter (2). Use the following procedure in order to install a transmitter. 1. Press the compartment latch forward in order to open the compartment door. 2. Remove the hook and loop patch from the top of the console. 3. Peel the adhesive backing from the hook and loop patch. 4. Firmly press the hook and loop patch to the back of the transmitter, as close to the center of the transmitter as possible. 5. Center the button on the transmitter over the button on the compartment door (3). Firmly press the transmitter into place. 6. Use the pegs inside the compartment door in order to make sure that the button on the compartment door makes contact with the button on the transmitter. 7. Add one peg at a time until the transmitter operates when the compartment door is closed and the button is pushed. Page 5637 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 1027 Oil Filter: Specifications Oil Filter ............................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) Oil Filter Fitting .................................................. ...................................................................................................................................... 35 Nm (26 ft. lbs.) Page 9779 Page 4242 Shift Boot: Service and Repair NV 3500 Control Lever and/or Boot Replacement Removal Procedure 1. Remove the shift lever from the shift tower. Do not remove the shift lever adjusting nut. 2. Remove the screws securing the boot to the panel. 3. Remove the boot from the shift tower. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the boot over the shift tower and secure to the panel with the screws. ^ Tighten the screws to 2 Nm (18 inch lbs.). 2. Install the shift lever to the shift tower. If required, center the shift lever with the adjusting nut. ^ Tighten the adjusting nut to 48 Nm (35 ft. lbs.). Page 5104 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Specifications Clutch Fluid: Specifications Hydraulic Clutch System Hydraulic Clutch Fluid (GM Part No. 12345347, in Canada 10953517, or equivalent DOT-3 brake fluid). Page 7922 Disclaimer Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 7425 Page 5601 Fuse Block - Underhood Connector C4 Part 3 Page 7671 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 4241 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shift boot screws. ^ Tighten the screws to 2 Nm (18 inch lbs.). 3. Install the shift lever to the shift tower. If required, center the shift lever with the adjusting nut. ^ Tighten the adjusting nut to 48 Nm (35 ft. lbs.). 4. If equipped Install the console and the 3 console nuts. ^ Tighten the nuts to 2 Nm (18 inch lbs.). Page 6515 Abbreviations And Meanings - Part 16 Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolt .......................................................................................................................... .................................................... 21 Nm (15 ft. lbs.) Remote Oil Filter Adapter Mounting Bracket Bolt ................................................................................................................................... 30 Nm (22 ft. lbs.) Remote Oil Filter Adapter Nut .................................................................................................. ............................................................... 25 Nm (18 ft. lbs.) Page 5534 Abbreviations And Meanings - Part 13 Page 6071 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 9594 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 4315 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 3012 1. Install the PCV valve cover using the following procedure: 1.1. Install a NEW seal (O-ring) on the PCV valve cover. 1.2. Lubricate the seal with clean engine oil. 1.3. Install the PCV valve cover in the upper intake manifold. 1.4. Turn and lock the PCV valve cover in position. 2. Connect the PCV valve hose assembly to the valve rocker arm cover. 3. Connect the PCV valve hose assembly to the intake manifold. Page 9553 Steps 17-23 The number below refers to the step number on the diagnostic table. 7. Listen for an audible click when the RR DEFOG relay operates. Command both the ON and OFF states of the RR DEFOG relay. Repeat the commands as necessary. Page 5950 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock. 14. Start the engine. Allow the engine to idle. 15. Turn the steering wheel 180-360 degrees in both directions 5 times. 16. Switch the ignition off. Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 17. Verify the fluid level. 18. Remove the pump reservoir cap. 19. Attach the J 43485 to the J 35555 or equivalent. 20. Place the J 43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 inch-Hg) maximum. 22. Wait 5 minutes. 23. Remove the J 43485 and the J 35555. 24. Verify the fluid level. Page 3476 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Page 1053 8. Remove the compressor hose assembly from the condenser. 9. Remove the O-ring seal and discard. INSTALLATION PROCEDURE 1. Install a new O-ring seal. 2. Install the compressor hose assembly to the condenser. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the hose to........................28 N.m (21 lb ft). 3. Install the lower radiator hose. 4. Install a new O-ring seal. Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 2519 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed based on the information from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Service and Repair Front Door Window Regulator: Service and Repair Window Regulator Replacement - Front Door Tools Required J 34940 Rivet Gun Removal Procedure 1. Remove the window. 2. Disconnect the power window motor electrical connector, if equipped. 3. Remove the electrical harness retainers, if equipped. 4. Drill out the rivets that secure the window regulator to the door. 5. Remove the window regulator from the door. 6. Remove the power window motor, if equipped. Installation Procedure 1. Install the power window motor, if equipped. 2. Install the window regulator to the door. 3. Install the rivets that secure the window regulator to the door using J 34940. 4. Connect the electrical connector, if equipped. 5. Connect the electrical harness retainers, if equipped. 6. Install the window. Page 1401 Wheels: Service and Repair Steel Wheel Repair Steel Wheel Repair Description Notice: ^ Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. ^ The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Electronic Components Electronic Components Compressor Hose Assembly Hose/Line HVAC: Service and Repair Compressor Hose Assembly COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor hose assembly bolt (1) and the washer (2). 3. Remove the compressor hose assembly from the compressor. 4. Remove the sealing washers. 5. Remove the compressor hose assembly from the accumulator. 6. Remove the O-ring seal and discard. 7. Remove the lower radiator hose. Page 4340 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 8379 WA800J/98 - WA805K/62 Page 8102 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT: Use a paste type grease, not a spray, for the following step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Page 501 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Page 7072 Page 5988 Locations View Page 546 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 6050 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 8482 10. Remove the left and right upper trim and lay it down inside the vehicle as seen in the illustration above. 11. Lower the headliner in order to gain access to the rear sunroof drain hoses. 12. Detach the top drain hose fastener from the roof by pulling out the clear colored clip from the body. Leave the hose unattached to the body at this clip. 13. Reroute the hoses as seen in the illustration above. 14. Raise the headliner and install the left and right upper trim. 15. Install the screw that retains the trim (left side only). Tighten Tighten the trim screw to 1.9 N.m (17 lb in). 16. Install the spare tire and holder if the tire is located inside the vehicle. 17. Install the jack assembly and the cover. 18. Reconnect the cargo lamp connector and install the rear upper garnish trim. 19. Install the end gate sill plate. Page 2049 Heater Hose: Service and Repair Heater Hose - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Release the outlet heater hose clamp using the J 38185 at the heater core. 3. Remove the outlet heater hose from the heater core. 4. Release the heater inlet hose clamp using the J 38185 at the intake manifold fitting. 5. Remove the heater inlet hose from the intake manifold fitting. 6. Release the heater outlet hose clamp using the J 38185 at the water pump. 7. Remove the heater outlet hose from the water pump. Page 810 Abbreviations And Meanings - Part 19 Page 6238 hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: - The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Page 2617 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Page 6687 11. Remove the bottom right heat/vent module mounting bolt from inside the vehicle. 12. On the Utility only, while an assistant inside the vehicle pulls the bottom right corner of the heat/vent module approximately 2.5 mm (1 in) back, remove the 2 heat/vent module mounting studs. IMPORTANT The heat/vent mounting stud has a flange on the inside and cannot be removed from under the hood. Stop turning the stud after the threads are off the heat/vent module. 13. Lower the vehicle. 14. On vehicles with a 2.2 L engine only, remove the engine wiring harness bracket located at the rear of the intake manifold. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 2.2 L. 15. Remove the HVAC module mounting bolt located at the lower left side of the heater core to heater hose connection. 16. Remove the HVAC module mounting nut located at the lower right side of the heater core to heater connection. 17. On the Utility only, loosen the HVAC module mounting studs until the threads are free from the heat/vent module. IMPORTANT The heat/vent mounting stud has a flange on the inside and cannot be removed from under the hood. Stop turning the stud after the threads are off the heat/vent module. 18. Disconnect all of the electrical connectors from the HVAC module. 19. Disconnect all of the vacuum lines from the heater assembly. 20. Disconnect the heater hoses from the heater core. 21. Remove the HVAC module from the vehicle. INSTALLATION PROCEDURE 1. If replacing the HVAC module, transfer the components from the old heat/vent module as necessary. 2. Install the HVAC module to the vehicle. IMPORTANT Before installing the HVAC module to the vehicle, ensure that the HVAC module mounting studs are located in the proper positions. Page 7142 Driver Information Center (DIC) C1 (w/o Trip Computer) Page 7812 1. Install the water deflector(s) to the rear side door. 2. Install the water deflector(s) to the door. 3. Use strip caulking as a sealant between the deflector(s) and the door if necessary. 4. Install the door speaker. * Speaker Replacement - Front Door * Speaker Replacement - Rear Door in Entertainment. 5. Install the door trim panel. * Trim Panel Replacement - Side Front Door * Trim Panel Replacement - Side Rear Door (Utility) Trim Panel Replacement - Side Rear Door (Extended Cab P/U Only) Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 9131 Abbreviations And Meanings - Part 9 Page 4970 Page 7522 For vehicles repaired under warranty use, the table. Disclaimer Page 3745 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Page 2808 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 1576 11. Remove the valve rocker arm cover gasket. 12. Discard the valve rocker arm cover gasket. 13. Clean the valve rocker arm cover in cleaning solvent. 14. Dry the valve rocker arm cover with compressed air. 15. Inspect the valve rocker arm cover for the following: ^ Damage to the PCV valve grommet (1) ^ Damage to the bolt holes (2) A damaged valve rocker arm cover may interfere with the valve rocker arms. ^ Damage to the exterior of the valve rocker arm cover (3) ^ Gouges or damage to the sealing surface (4) ^ Damage to the oil fill tube grommet (5) ^ Restrictions to the ventilation system passages Installation Procedure Important: Do not reuse the valve cover gasket or the valve rocker arm cover bolt grommets. Page 4572 4. Remove the brake rotor. 5. Remove the axle shaft. 6. Remove the park brake shoe. Page 8724 Door Lock Cylinder Switch - Driver (w/o RKE) Page 1685 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil into a suitable container. 3. For 2WD vehicles, remove the oil filter from the oil filter adapter. 4. For Four-Wheel Drive vehicles, open the access panel in the steering linkage shield. 5. Remove the oil filter from the remote oil filter adapter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Page 9011 Abbreviations And Meanings - Part 23 Page 6139 17. Remove the upper ball joint. Installation Procedure 1. Install a new upper ball joint to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper ball joint retaining bolts and nuts. Tighten the upper ball joint retaining nuts to 23 Nm (17 ft. lbs.). 3. Install the upper ball joint to the steering knuckle. 4. Install the upper ball joint stud nut. ^ Tighten the upper ball joint stud nut to 83 Nm (61 ft. lbs.). ^ Tighten the stud nut in order to align the slot in the stud nut with the hole in the stud. 5. Install a new cotter pin. Page 4633 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front (Single Piston) Brake Caliper Overhaul - Front (Single A Piston) Tools Required ^ J26267 Piston Seal Installer Disassembly Procedure 1. Drain all of the brake fluid from the caliper. 2. Install a piece of wood or shop towels between the caliper and the piston. 3. Cover the brake caliper with a shop rag. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 4. Apply only enough compressed air to the brake caliper to remove the piston. 5. Remove the shop rag cover from the brake caliper. 6. Remove the piece of wood or shop towels from the brake caliper. 7. Remove the boot from the front brake caliper. Important: When removing the, front brake caliper piston seal, use a non metallic tool. Page 3600 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 9079 Page 7742 5. If the studs are bent or missing, use a center punch at the center of the missing location. Using a.5" drill, drill a hole. 6. Install a rivnut into the frame. 7. Install bolt (1) in rivnuts. Tighten to 35 N.m (26 lb ft). Door Sill Plate Replacement Scuff Plate: Service and Repair Door Sill Plate Replacement Door Sill Plate Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Use the J 38778 in order to remove the door sill trim plate from the vehicle. Installation Procedure Install the door sill trim plate to the vehicle. Align the retainers along the door sill and press into place. Page 516 Intake Air Temperature (IAT) Sensor Page 1169 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 6664 12. Fill the engine cooling system. Refer to Draining and Filling Cooling System in Cooling System. Page 3258 Disclaimer Page 8320 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Locations Oxygen Sensor: Locations Heated Oxygen Sensors (HO2S) Page 4014 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Page 8620 SEAT CUSHION TRIM COVER AND PAD REPLACEMENT (BUCKET) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the cupholder and bracket, if equipped. 3. Remove the seat back recliner assembly, if equipped. 4. Remove the trim plate. 5. Separate the J-strips from the seat bottom frame. 6. Separate the hook and loop strips (1) that retain the seat pad (3) to the seat cover (2). Flywheel to Torque Converter Bolts Flex Plate: Specifications Flywheel to Torque Converter Bolts Flywheel to torque converter bolts ........................................................................................................................................................... 60 Nm (44 ft. lbs.) Page 1731 Engine Oil Pressure (EOP) Sensor Page 9190 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 8965 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 1853 Steps 13-14 Page 9726 Abbreviations And Meanings - Part 16 Page 8685 Abbreviations And Meanings - Part 5 Page 9848 Door Lock And Window Switch - Driver C1 Part 2 Page 2943 Automatic Transmission, RH Page 8055 3. Raise the frame slightly on the hoist. 4. Install the lower cushion. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the frame cushion bolts. Tighten the bolts to 70 N.m (52 lb ft). 6. Lower the hoist. Page 2231 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 1539 Engine Block Heater: Service and Repair Heater Cord Coolant Heater Cord Replacement Removal Procedure 1. Remove the coolant heater cord bolt and the retainer. 2. Cut the plastic ties and remove the heater cord from the wiring harness. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Disconnect the coolant heater cord electrical connector. 5. Remove the coolant heater cord. Installation Procedure 1. Connect the coolant heater electrical connector. 2. Install the coolant heater cord. 3. Lower the vehicle. 4. Install the coolant heater cord to the wiring harness. 5. Install the plastic ties to retain the coolant heater cord to the wiring harness. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the coolant heater cord retainer and bolt. Tighten the coolant heater cord bolt to 8 Nm (71 inch lbs.). Page 8781 Sunroof / Moonroof Switch: Description and Operation SUNROOF SWITCH The sunroof switch has three positions: - Close - Off, in rest position - Open Pressing the forward portion of the sunroof switch will slide the sunroof window to the close position. Pressing the rearward portion of the sunroof switch will raise the rear edge of the sunroof window and then will move the sunroof window from the close position to the full open position, unless the switch is released. Page 9385 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8699 Abbreviations And Meanings - Part 19 Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Light Switch Mounting Bolt 35 inch lbs. Page 6057 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 5425 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 4616 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Door Window Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Window The outer door weatherstrip is used in order to seal the inner and outer door panels and the window at the belt line. The outer door weatherstrip can be replaced. Do not remove the inner sealing strip since the strip is stapled to the trim panel. Removal Procedure 1. Open the window. 2. Remove outer door weather strip from the door. Installation Procedure 1. Position the weatherstrip and press it into place. 2. Close the window. Page 5776 C433 (Body Harness To Defogger Grid Harness) Page 9473 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 2586 Powertrain Control Module (PCM) Page 9467 Page 5029 Abbreviations And Meanings - Part 18 Latch Replacement - End Gate Tailgate Latch: Service and Repair Latch Replacement - End Gate Latch Replacement - End Gate Removal Procedure 1. Open the endgate. 2. Remove the endgate trim panel. 3. Remove the endgate latch rod from the endgate latch. 4. Remove the bolts that retain the endgate latch to the endgate. 5. Remove the endgate latch from the vehicle. Installation Procedure 1. Install the endgate latch to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the endgate latch to the endgate. Tighten the bolts to 10 N.m (88 lb in). 3. Install the endgate latch rod to the endgate latch. 4. Install the endgate trim panel. Page 2501 Body Control Module (BCM) C2 Part 3 NV 1500 Vehicle Speed Sensor Page 1400 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Over spray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Wheel Alignment Specifications Wheel Alignment Specifications Page 3146 5. Install the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 8978 Arrows And Symbols Uses various symbols in order to describe different service operations Page 7424 Page 5317 C203 (Body Harness To IP Harness) Part 5 Page 9818 Abbreviations And Meanings - Part 4 Page 6507 Abbreviations And Meanings - Part 8 Page 9038 6. Remove the screw at the front of the console. 7. Pull downward on the rear of the console in order to remove the sunroof console from the roof. 8. Disconnect the electrical connectors (1, 5, 6) as needed. 9. Remove the sunroof console. Note: Use caution not to damage or crease the headliner while repositioning. 10. Reposition the front of the headliner down and out of the way of the compass mounting bracket. 11. Remove the screw that retains the sunroof console mounting bracket to the roof. 12. Remove the compass sensor mounting bracket from the vehicle. 13. Remove the front center clip-in retainer from the compass sensor mounting bracket. 14. Install the clip-in retainer on the new compass sensor mounting bracket, P/N 15106819. 15. Trim the headliner as shown above in order to allow clearance for the new compass mounting sensor bracket. Follow the dimensions below for the trimming of the sensor bracket. ^ A = 71 mm (2.8 in) ^ B = 19 mm (0.75 in) ^ C = Center line of headliner ^ D = 9.5 mm (0.375 in) Page 2484 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Remove the MAF sensor from the air cleaner cover and air cleaner outlet duct by loosening the hose clamps. NOTE: Refer to Mass Air Flow (MAF) Handling Notice in Service Precautions. INSTALLATION PROCEDURE Page 3718 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Use the J 38778 in order to remove the door auxiliary weatherstrip from the vehicle. Installation Procedure 1. Install the door auxiliary weatherstrip to the vehicle. 2. Position the weatherstrip and press the weatherstrip into place. Ensure that the retaining clips lock into place. Page 7383 Page 2670 Arrows And Symbols Uses various symbols in order to describe different service operations Page 1629 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 2. Remove the drive belt. 3. Slowly release the tension on the drive belt tensioner arm. Installation Procedure 1. Route the drive belt over all the pulleys except the drive belt tensioner pulley. 2. Observe the drive belt routing for the vehicles without air conditioning. Locations LF Front Fender Area Page 5908 Page 2590 Powertrain Control Module (PCM) Connector C1 Part 3 Page 525 Engine Harness Rear (4.3L) Page 7245 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 8970 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Specifications Trailing Arm: Specifications Rear Tie Rod Axle Bracket Nuts 39 ft. lbs. Rear Tie Rod Bolt to Axle Bracket Nut 45 ft. lbs. Rear Tie Rod to Frame Bracket Nut 45 ft. lbs. Page 673 Clutch Start Switch Page 9520 Abbreviations And Meanings - Part 16 Page 8645 Page 5873 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 8939 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5291 C413 (Engate Harness To Body Harness) Instruments - Inaccurate/Erratic Compass Operation Compass: All Technical Service Bulletins Instruments - Inaccurate/Erratic Compass Operation Bulletin No.: 03-08-49-008A Date: February 26, 2004 TECHNICAL Subject: Erratic or Inaccurate Compass Operation with Use of Power Sunroof (Replace Compass Sensor Mounting Bracket and Calibrate Compass) Models: 1999-2004 Chevrolet Blazer 1999-2004 GMC Jimmy 1999-2001 Oldsmobile Bravada with Roof, Sun, Glass Sliding, Electric (RPO CF5) and Console Roof Interior, Custom, Compass and Outside Temperature (RPO DK7) or Console Roof Interior, Deluxe (RPO DK8) Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 03-08-49-008 (Section 08 - Body and Accessories). Condition Some customers may comment that the compass is intermittently erratic or inaccurate while operating the power sunroof. The compass may stay erratic or inaccurate while the power sunroof is open. Cause The sunroof module cable may become magnetized with the operation of the sunroof, producing a false signal to the compass sensor. Correction Follow the service procedure below to relocate the compass sensor by replacing the compass sensor bracket. Compass Sensor Mounting Bracket Replacement Procedure 1. Remove the rearview mirror. 2. Remove the sunshades and the retainers. 3. Remove the right front assist handle. 4. Remove the windshield garnish moldings. 5. Remove the body lock pillar trim panels. Page 9352 Page 5556 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Schematics Page 1139 2. For a RWD vehicle, install the oil filter to the oil filter adapter. 3. For Four-Wheel Drive vehicles, install the oil filter to the remote oil filter adapter. 4. Tighten the oil filter following the instructions on the filter. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan drain plug into the oil pan. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the crankcase with the proper capacity and quality of engine oil. 8. Operate the engine and check for leaks and oil pressure. 9. For a Four-Wheel Drive vehicles, close the access panel in the steering linkage shield. Page 3055 3. Tighten the air cleaner cover wingnuts. Page 2168 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector (3). 2. Remove 2 screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 3. Remove the ignition control module and heat sink. INSTALLATION PROCEDURE 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the 2 screws (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). Page 26 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 9090 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 8869 Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Door Bottom Sealing Strip Replacement - Door Bottom Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Use the J 38778 in order to remove the door bottom weatherstrip from the door. Installation Procedure 1. Position the door bottom weatherstrip. 2. Press the weatherstrip into place. Page 3904 Disclaimer Page 3552 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 1750 13. Disconnect the following electrical connectors: ^ The fuel meter body assembly (1) ^ The EVAP canister purge solenoid valve (2) ^ The Manifold Air Pressure (MAP) sensor (3) 14. Disconnect the following electrical connectors: ^ The ignition coil (2) ^ The Ignition Control Module (ICM) (1) ^ The generator (4) 15. Disconnect the following electrical connectors: ^ The Idle Air Control (IAC) motor (3) ^ The Throttle Position (TP) sensor (2) ^ The A/C compressor cutoff switch, if equipped (5) Page 8999 Abbreviations And Meanings - Part 11 Page 5709 C433 (Body Harness To Defogger Grid Harness) Page 5681 C217 (Body Harness To IP Harness) OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 6511 Abbreviations And Meanings - Part 12 Page 9841 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Page 2723 Steps 12-14 Page 6669 3. Remove the pressure relief valve from the rear head of the A/C compressor. Page 106 Sunroof Control Module C2 Page 8386 WA8554/40 - WA8555/41 Page 9662 Page 1763 4. Remove the air cleaner outlet duct from the throttle body. 5. Disconnect the accelerator cable from the throttle body. 6. Remove the accelerator cable from the accelerator control cable bracket. Page 2024 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 6795 2. Install the SDM (2) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 12 N.m (106 lb in). 5. Install the SDM harness connector (3) to the SDM (2). 6. Install the CPA (4) to the SDM harness connector (3). 7. Tape the cut carpet to cover the SDM. 8. Install the floor console, if equipped. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and to SIR Disabling and Enabling Zone 3. Page 2155 Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The Powertrain Control Module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The Ignition Control (IC) - The Knock Sensor (KS) system - The Evaporative Emissions (EVAP) system - The Secondary Air Injection (AIR) system (if equipped) - The Exhaust Gas Recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the Malfunction Indicator Lamp (MIL). When the PCM detects a malfunction, the PCM stores a Diagnostic Trouble Code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. Locations Endgate Harness Routing View Page 4136 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Front and Rear Grade ......................................................................................................................... .................................................................................................... GL-5 Viscosity ................................ .............................................................................................................................................................. ..................... 80W-90 Page 2012 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 1546 5. Use the J 23523-F in order to press the crankshaft balancer onto the crankshaft. 5.1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten the J 23523-F plate bolts to 25 Nm (18 ft. lbs.). 5.2. Install the J 23523-F screw into the end for the crankshaft. 5.3. Install the J 23523-F bearing, the washer, and the nut onto the screw. 5.4. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring. 6. Remove the J 23523-F. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the crankshaft pulley and bolts. Tighten the crankshaft pulley bolts to 58 Nm (43 ft. lbs.). Page 5330 C211 (Steering Column Harness To Body Harness) Part 2 Page 8091 Carpet: Removal and Replacement Mat/Carpet Replacement - Front Floor (Extended Cab) Mat/Carpet Replacement - Front Floor (Extended Cab) Removal Procedure 1. Remove the front seat. 2. Remove the jack cover from the vehicle. 3. Remove the jack from the vehicle. 4. Remove the door sill trim plates. 5. Remove the floor console or cup holder, if equipped. 6. Remove the body side trim panels. 7. For vehicles with the extended cab with rear side door, remove the C-pillar trim panel. Refer to Trim Replacement - Third Pillar (Extended Cab Pickup w/ Rear Side Door) Trim Replacement - Third Pillar (4-Door Utility). 8. Remove the body hinge trim panels. 9. Remove the carpet or the mat from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet or the mat to the vehicle. 2. Install the body hinge trim panels. 3. For vehicles with the extended cab with rear side door, install the C-pillar trim panel. Refer to Trim Replacement - Third Pillar (Extended Cab Pickup w/ Rear Side Door) Trim Replacement - Third Pillar (4-Door Utility). 4. Install the body side trim panels. 5. Install the floor console or cup holder, if equipped. 6. Install the door sill trim plates. 7. Install the jack to the vehicle. 8. Install the jack cover to the vehicle. 9. Install the front seats. Mat/Carpet Replacement - Front Floor (Utility) Page 9487 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 9083 Page 7130 Abbreviations And Meanings - Part 23 Page 5702 C403 (Body Harness To LH Tail Lamp Harness) (Export) Page 4547 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Page 9250 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Page 4644 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol. 2. Dry the brake caliper pin bolts using non lubricated, compressed filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper bolts. 4. DO NOT apply the lubricant to the brake pad hardware. 5. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the brake caliper bolts. Tighten the brake caliper bolts to 31 Nm (23 ft. lbs.). Page 9262 Page 4887 Equivalent - Decimal And Metric Part 1 Page 3649 Case: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 6011 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Page 1251 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the left insulator/closeout panel. 2. Remove the screw (1) securing the junction block (2) to the instrument panel. 3. Peel the wrapping (3) on the wiring harness back to give more play in the individual wires going to the junction block. 4. Remove each wire and terminal from the old junction block. INSTALLATION PROCEDURE 1. Install each wire and terminal in the new junction block. 2. Rewrap the wrapping (3) on the wiring harness. 3. Install the junction block (2) to the instrument panel with the screw (1). 4. Install the left insulator/closeout panel. Page 4864 Page 9092 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 6100 Abbreviations And Meanings - Part 23 Page 772 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Power Mirror Switch Replacement Power Mirror Switch: Service and Repair Power Mirror Switch Replacement POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Locations Inflatable Restraint Steering Wheel Module/Horn Pad Specifications Oil Level Sensor: Specifications Engine Oil Level Sensor ...................................................................................................................... ................................................ 13 Nm (115 inch lbs.) Page 2158 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the powertrain control module (PCM) or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. NOTE: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. IMPORTANT: Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing/replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 2. Move the PCM retention bar and retainer away from the PCM. 3. Remove the PCM from the PCM mounting bracket. Page 9612 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 6089 Abbreviations And Meanings - Part 12 Page 5304 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 2 Page 8439 Sunroof / Moonroof Motor: Diagrams Sunroof Motor Page 5242 C117 (Engine Harness To AIR Harness, w/ California Emissions) Page 2760 2. Install the HO2S (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Page 2672 Conversion English/Metric Part 2 Page 8984 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Service and Repair Front Door Window Motor: Service and Repair Motor Replacement - Power Window Removal Procedure Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 1. Remove the window regulator. 2. Drill a hole through the window regulator and the sector gear. 3. Install a bolt and a nut through the hole in order to lock the sector gear in position. 4. Drill out the rivets that secure the power window motor to the window regulator. 5. Remove the power window motor from the window regulator. Installation Procedure 1. Install the power window motor to the window regulator. Important: Remove the nut and the bolt that were used in order to secure the sector gear in position. 2. Install the rivets in order to secure the power window motor to the window regulator. 3. Install the window regulator. Page 9611 Conversion English/Metric Part 2 Page 4645 7. Install the NEW metal (copper) gaskets to the brake hope and the bolt. Notice: Refer to Brake Hose Installation Notice in Service Precautions. 8. Install the rear brake hose bolt. Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Brake Caliper Overhaul - Front (Single Piston) Brake Caliper Overhaul - Front (Single A Piston) Tools Required ^ J26267 Piston Seal Installer Disassembly Procedure 1. Drain all of the brake fluid from the caliper. 2. Install a piece of wood or shop towels between the caliper and the piston. 3. Cover the brake caliper with a shop rag. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 4. Apply only enough compressed air to the brake caliper to remove the piston. 5. Remove the shop rag cover from the brake caliper. 6. Remove the piece of wood or shop towels from the brake caliper. Page 8292 Power Mirror Switch: Service and Repair Power Folding Outside Mirror Switch POWER FOLDING OUTSIDE MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the folding outside mirror switch by carefully using a flat-bladed tool in order to pry up on the leading edge. 3. Remove the accessory switch panel from the armrest. Use a flat-bladed tool in order to carefully pry the cover up at the front leading edge leaving the electrical connections connected. 4. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Install the power accessory switch mounting panel to the armrest. Ensure that the retainers lock into place. 3. Install the power folding mirror switch to the door trim panel. Ensure that the retainers lock into place. 4. Connect the battery negative cable. Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 186 The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. NOT RUN SCC (NOT RUN SINCE CODE CLEAR): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 9470 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 4542 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Diagrams Specifications Camshaft: Specifications Camshaft Camshaft End Play ........................................................................................................................................ 0.0254 0.2286 mm (0.0010 - 0.0090 inch) Camshaft Journal Diameter ........................................................................................................................... 47.440 - 47.490 mm (1.8677 - 1.8696 inch) Camshaft Journal Out-of-Round .................................................................................................................................................... 0.025 mm (0.001 inch) Camshaft Lobe Lift - Exhaust ................................................................................................................................... 7.20 - 7.30 mm (0.283 - 0.287 inch) Camshaft Lobe Lift - Intake ...................................................................................................................................... 6.97 - 7.07 mm (0.274 - 0.278 inch) Camshaft Runout ......................................................................................... ................................................................................ 0.065 mm (0.0026 inch) Camshaft Retainer Bolt .............................................................................................................................................................. ..... 12 Nm (106 inch lbs.) Page 7669 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 6455 Page 6706 Refrigerant Filter: Service and Repair A/C Refrigerant Filter Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the PCM. 3. Remove the engine coolant reservoir. 4. Remove the nuts (4) from the A/C refrigerant filter (1). IMPORTANT:The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 5. Remove the A/C refrigerant filter (1) from the evaporator tube. INSTALLATION PROCEDURE 1. Coat the new O-rings (2) with 525 viscosity refrigerant oil. 2. Install the new O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (1) to the evaporator tube with the flow arrow pointing towards the evaporator. 4. Install the nuts (4) to the A/C refrigerant filter (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nuts to..............15 N.m (11 lb ft). Description and Operation Brake Warning Indicator: Description and Operation Brake Warning System Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: ^ The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The EBCM detects an ABS malfunction which disables dynamic rear proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. ^ The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 5541 Abbreviations And Meanings - Part 20 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Cellular Phone: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 6080 Abbreviations And Meanings - Part 3 Page 2835 3. Connect the ECT sensor harness connector. 4. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 5. Install the air cleaner outlet duct assembly and tighten the wing nuts. 6. Connect the negative battery cable. Page 8943 Page 6136 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower ball stud nut. Tighten the lower ball stud nut to 108 Nm (79 ft. lbs.). Tighten in order to align the slot in the stud nut with the hole in the stud. 4. Install a new cotter pin to the stud. 5. Lubricate the lower ball joint. 6. Install the brake caliper. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Check the front wheel alignment. Page 1028 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil into a suitable container. 3. For 2WD vehicles, remove the oil filter from the oil filter adapter. 4. For Four-Wheel Drive vehicles, open the access panel in the steering linkage shield. 5. Remove the oil filter from the remote oil filter adapter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed based on the information from the PCM. The PCM converts the data from the engine speed sensor to a 2 pulses/engine revolution signal. The IPC uses the engine speed signal circuit from the PCM in order to calculate the engine speed. The tachometer defaults to 0 rpm if a malfunction in the engine speed signal circuit exists. Page 782 Conversion English/Metric Part 1 Page 3054 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover wingnuts. 2. Remove the air cleaner cover. 3. Remove the air cleaner element. 4. Clear out any debris in the air cleaner housing. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner housing. 2. Install the air cleaner cover. Page 6181 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the balance shaft retainer and bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 4. Install the balance shaft driven gear onto the balance shaft. 5. If reusing the fastener, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the balance shaft driven gear bolt. 6. Install the balance shaft driven gear bolt. 6.1. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Install the balance shaft driven gear bolt. Tighten the balance shaft driven gear bolt to 20 Nm (15 ft. lbs.). Using the J 36660-A rotate the balance shaft driven gear bolt an additional 35 degrees. 7. Remove the wrench from the balance shaft. 8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case. Page 8995 Abbreviations And Meanings - Part 7 Page 4327 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side Page 2703 Abbreviations And Meanings - Part 23 Page 2151 Powertrain Control Module (PCM) Connector C2 Part 3 Page 7301 Abbreviations And Meanings - Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolt ..................................................................................................................... .................................................... 50 Nm (37 ft. lbs.) Generator and Drive Belt Tensioner Bracket Bolt to Engine ................................................................................................................... 41 Nm (30 ft. lbs.) Generator and Drive Belt Tensioner Bracket Stud Nut ............................................................................................................................ 41 Nm (30 ft. lbs.) Generator and Drive Belt Tensioner Bracket Stud to Engine ................................................................................................................... 20 Nm (15 ft. lbs.) Page 268 Seat Lumbar Switch - Front Passenger Part 2 Page 5587 Fuse Block - Underhood Connector C1 Part 4 Page 2952 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Page 1807 5. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole). 6. Install camshaft sprocket bolts. Tighten the camshaft sprocket bolts to 25 Nm (18 ft. lbs.). 7. Install the crankshaft position sensor reluctor ring. 7.1. Align the keyway on the crankshaft position sensor reluctor ring with the crankshaft balancer key in the crankshaft. 7.2. Use the J 5590 in order to push the crankshaft position sensor reluctor ring onto the crankshaft until completely seated against the crankshaft Page 2802 4. Slide the PCM retainer into the PCM bracket slots. 5. Pull the PCM retention bar into position. Page 4597 5. Using a punch and hammer, remove and discard the knockout plug in the backing plate (1) which is directly behind the star wheel adjuster. 6. Install the brake drum. 7. Insert a flat bladed screw driver (1) and move the adjuster lever away from the star wheel. 8. Using a brake adjusting tool, rotate the brake adjuster (2) until the amount of drag is equal on the left and right rear brake drums. 9. Apply the brake pedal two times in order to center the brake shoes on the locating pins. 10. Check the drums again for light drag. Adjust as necessary. 11. Install an adjusting hole cover in the backing plate. 12. Lower the vehicle. Refer to Vehicle Lifting. 13. Check the park brake adjustment. Page 5313 C203 (Body Harness To IP Harness) Part 1 Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 895 Disclaimer Page 4029 Page 7656 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Specifications Valve Seat: Specifications Valve System Valves - Valve Face Angle .................................................................................................................. .............................................................. 45 degrees Valves - Valve Seat Angle ................................. ............................................................................................................................................... 46 degrees Valves - Valve Seat Runout ............................................................................................................................................................. 0.05 mm (0.002 inch) Valves - Valve Seat Width - Intake ....................................................................................................................... 1.016 - 1.651 mm (0.040 - 0.065 inch) Valves - Valve Seat Width - Exhaust .................................................................................................................... 1.651 - 2.489 mm (0.065 - 0.098 inch) Page 9708 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 4354 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 8321 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 4894 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in. 1.52 mm Page 5434 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 8450 Sunroof / Moonroof Switch: Diagrams Sunroof Motor (Sunroof Switch C1) Page 2058 For vehicles repaired under warranty, use the table. Disclaimer Page 8779 Sunroof Switch Page 4448 Disclaimer Page 7929 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 3120 Fuel Meter Body: Service and Repair FUEL METER BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE An 8-digit part identification number is on a mylar label affixed to the fuel meter body assembly. Refer to this number if servicing or part replacement is required. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Remove the upper intake manifold assembly. 4. Before removal, clean the fuel meter body assembly with a spray type engine cleaner, GM X-30A or the equivalent, if necessary. Follow the package instructions. DO NOT soak fuel meter body assemblies in liquid cleaning solvent. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 5. Squeeze the poppet nozzle locking tabs together while lifting the nozzle out of the casting socket. NOTE: Cover the injector sockets in order to prevent dirt and other contaminants from entering the open fuel passages. IMPORTANT: When disconnecting the poppet nozzles, remember the sequence in order to ensure correct poppet nozzle placement to each cylinder. 6. Remove the fuel meter body from the bracket by releasing the lock tabs on the bracket. INSTALLATION PROCEDURE Molding Replacement - Body Side (Chevrolet) Lower Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Chevrolet) Molding Replacement - Body Side (Chevrolet) Tools Required J 25070Heat Gun Removal Procedure 1. Heat the body side molding using a J 25070. Hold the heat gun approximately 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or chip the paint. 2. Peel the body side molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel and the back of the body side molding using a 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 4. Clean the body panel using Varnish Makers and Painters (VMP) naphtha. Installation Procedure 1. Warm body panel with a heat lamp or heat gun to a minimum of 21°C (70°F). 2. Peel the backing from the front end of the body side molding. Important: Do not touch the adhesive backing. 3. Press the body side molding to the body while continuing to remove the backing. 4. Hand roll the body side molding to the body in order to ensure proper adhesion. Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Page 3854 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the electrical connector from the sensor. 4. Remove the bolt (2). 5. Using a twisting and pulling motion, remove the vehicle speed sensor (1) from the case. 6. Remove and discard the O-ring seal (3). Installation Procedure 1. Install the new O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with clean transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Remove the drain pan. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 8004 Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Window Strut Replacement - Lift Gate Window Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate window. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Remove the retainer from the hinge pin. The hinge pin is located at the upper end of the liftgate window strut. Discard the retainer. 3. Remove the hinge pin from the upper end of the liftgate window strut. Discard the hinge pin. 4. Lift up the retainer clips on the liftgate window struts using a small flat-bladed tool. 5. Remove the lower end of the liftgate window struts from the ball joint. 6. Remove the liftgate window struts from the liftgate window. Installation Procedure 1. Position the liftgate window struts to the liftgate window. 2. Install the lower end of the liftgate window struts to the ball joint. Press in to place until fully seated. 3. Install the new hinge pin to the upper end of the liftgate window strut. 4. Install the new retainer to the hinge pin. 5. Remove the support from the liftgate window. 6. Close the liftgate window. Page 5769 C403 (Body Harness To LH Tail Lamp Harness) (Export) Page 597 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 8591 2. Remove the recliner handle (1) from the seat bottom. INSTALLATION PROCEDURE 1. Install the recliner handle (1) to the seat bottom. 2. Install the retaining screw to secure the handle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the handle retaining screw to 1.5 N.m (14 lb in). Seat Back Recliner Replacement - Front SEAT BACK RECLINER REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the recliner handle. 2. Remove the recliner cover. 3. Remove the inertia latch from the recliner assembly. 4. Remove the recliner assembly bolts. Page 2297 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Door Striker Replacement Front Door Striker: Service and Repair Door Striker Replacement Striker Replacement - Door Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the front door lower striker bolt. 2. Remove the rear door lower striker bolt. 3. Loosen the upper striker bolts enough in order to rotate the striker and the spacer (if equipped) away from the lower bolt hole. 4. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 5. Remove the following components: * The upper striker bolt * The spacer (if equipped) * The striker Installation Procedure 1. Install the following components: * The striker * The spacer (if equipped) * The upper striker bolt 2. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 3. Remove the lower bolt. 4. Rotate the striker and the spacer (if equipped) in order to align the lower threaded hole in the striker backing plate. Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 2807 Mass Air Flow (MAF) Sensor Page 5352 C402 (Body Harness To RH Tail Lamp Harness) (Domestic) Page 2878 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Remove the fuel sender assembly. 6. Disconnect the fuel pump electrical connector (5). 7. Remove the fuel level sensor electrical connector retaining clip (6). 8. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 9. Remove the fuel level sensor retaining clip (4). 10. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 7401 For vehicles repaired under warranty use, the table. Disclaimer Page 6032 Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 4265 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 5262 C211 (Steering Column Harness To Body Harness) Part 1 Page 4916 Abbreviations And Meanings - Part 16 Page 5108 Abbreviations And Meanings - Part 1 Page 7109 Abbreviations And Meanings - Part 2 Page 9197 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 4053 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 3643 6. Tighten the bolt on the J 29714-A in order to compress the servo cover. 7. Install the servo cover retaining ring. 8. Remove the J29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the oil pan bolt. & Tighten the oil pan bolt to 11 Nm (97 inch lbs.). 10. Connect the oil cooler lines to the transmission, if removed. 11. Raise the transmission into place. 12. Remove the drain pan from under the vehicle. 13. Install the exhaust manifold pipe. 14. Install the transmission support. 15. Remove the transmission jack. 16. Lower the vehicle. 17. Fill the transmission to the proper level with DEXRON (R)III transmission fluid. Page 5373 C601 (Body Harness To Door Harness, RH Front) (W/O Power Locks/Windows) Page 3121 1. Install the fuel meter body in the intake manifold. 2. Push the fuel meter body into the bracket. Make sure all of the tabs are locked into place. 3. Push the poppet nozzles into the casting sockets. CAUTION: Verify that the poppet nozzles are firmly seated and locked in their casting sockets in order to reduce the risk of fire and personal injury. An unlocked poppet nozzle could work loose from its socket and produce a fuel leak. IMPORTANT: The fuel meter body assemblies are numbered to indicate poppet nozzle order. 4. Inspect the poppet nozzles in order to ensure they are firmly seated and locked in the casting sockets. 5. Install the upper intake manifold assembly. 6. Tighten the fuel filler cap. 7. Connect the negative battery cable. 8. Inspect for leaks. 8.1. Turn ON the ignition for 2 seconds. 8.2. Turn OFF the ignition for 10 seconds. 8.3. Turn ON the ignition. 8.4. Inspect for fuel leaks. Diagrams Window Lockout Switch Page 1713 4. Install the remote oil filter inlet and outlet clip and bolt to the oil pan. Tighten the remote oil filter inlet and outlet hose clip bolt to 10 Nm (89 inch lbs.). 5. Install the steering linkage shield, if equipped. 6. Lower the vehicle. 7. Operate the engine and check for leaks. 8. Inspect the engine oil level and fill to the proper level. Page 1913 9. Install the distributor cap. 10. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to installation procedure 2 if malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the malfunction indicator lamp (MIL) is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. INSTALLATION PROCEDURE 2 Page 2603 4. Slide the PCM retainer into the PCM bracket slots. 5. Pull the PCM retention bar into position. Fuel Hose/Pipes Replacement - Engine Compartment Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 3. Remove the air cleaner outlet duct. 4. Disconnect the spark plug wires from the left side of the distributor. 5. Disconnect the chassis fuel feed and return pipes (1) at the engine compartment fuel feed and return pipes. 6. Remove the injector fuel inlet and outlet pipe retainer nuts. 7. Remove the injector fuel inlet and the outlet pipe retainer. 8. Remove the rear fuel pipe bracket retaining bolt. Page 4505 7. Remove the boot from the front brake caliper. Important: When removing the, front brake caliper piston seal, use a non metallic tool. 8. Remove the front brake caliper piston seal. 9. Remove the bleeder valve from the brake caliper body. 10. Clean the following items with denatured alcohol. ^ The bleeder valve ^ The brake caliper body bore ^ The brake caliper piston Important: If the corrosion cannot be removed, replace the brake caliper housing and piston. 11. Using a crocus cloth, clean the corrosion from the brake caliper bore. 12. Dry the parts using non lubricated, filtered compressed air. 13. Replace the brake caliper or the piston if any of the following conditions exist: Page 2966 Transfer Case (With RPO Code NP8) Harness Routing View Page 4820 Clutch Start Switch Page 4416 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4069 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 8503 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement With RPO Code Zrx/Extreme W/ CF5 SUNROOF WINDOW REPLACEMENT WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. Remove the window panel garnish molding (1). 2. Remove the 2 front screws (2) that retain the sunroof window to the sunroof slider arm. 3. Remove the 2 rear screws (2) that retain the sunroof window (1) to the sunroof slider arm. Page 9539 Heated Glass Element: Description and Operation REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control assembly - RR DEFOG relay - Rear window defogger grid REAR WINDOW DEFOGGER OPERATION Battery positive voltage is supplied to the RR DEFOG relay switched input. Ignition voltage is supplied through the IGN E fuse, in the underhood fuse block, to the RR DEFOG relay coil. When you start the engine, and depress the rear window defogger switch. The HVAC control assembly illuminates the rear window defogger indicator and energizes the RR DEFOG relay by grounding the control circuit of the relay. This allows battery positive voltage from the relay switched input through the switch contacts and out the relay switched output to the RR DEFOG fuse and then to the rear window defogger grid. Ground for the rear window defogger grid is provided by G420. When you start the engine and press the rear window defogger switch for the first time, the defogger cycle lasts for 10 minutes. Further operation results in 5 minute defogger cycles. The defogger cycle resets to 10 minutes when you cycle the ignition to the OFF position and then start the engine. Page 2641 Specifications Drive Pulley: Specifications Fan and Water Pump Pulley Bolt ............................................................................................................................................................. 25 Nm (18 ft. lbs.) Water Pump Pulley Bolts ....................................................................................... ................................................................................... 25 Nm (18 ft. lbs.) Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 5549 Registered And Non-Registered Trademarks - Part 1 Page 9057 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 877 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 8640 Page 1623 drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Drive Belt Excessive Wear Diagnosis Step 1 - 6 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening Removal Procedure 1. Open the endgate or the liftgate. 2. Remove the weatherstrip molding from the pinch-weld flange. 3. Firmly grip the weatherstrip. 4. Pull the weatherstrip out and away from the vehicle. Installation Procedure 1. Push the weatherstrip onto the pinch weld flange, beginning from the top corner of the endgate opening. 2. Completely seat the weatherstrip around the endgate or the liftgate opening. Page 7492 5. Turn the DRL sensor counterclockwise 1/4 turn in order to install. 6. Install the radio front speaker grille. 7. Install the radio front speaker grille screws. Tighten Tighten the radio front speaker screws to 1.9 N.m (17 lb in). 8. Inspect for proper circuit operation. Page 2831 Engine, LR Page 5122 Abbreviations And Meanings - Part 15 Page 1706 7. Remove the engine oil cooler line from the radiator. 8. Remove the engine oil cooler lines. 9. Clean all of the components in a suitable solvent, and dry them with compressed air. 10. Inspect the fittings, the connectors, the cooler for damage, distortion, or restriction. Replace parts a necessary. 11. Flush the engine oil cooler and engine oil cooler lines with the same type of engine oil normally circulating through the engine. Installation Procedure Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. 1. Install the engine oil cooler lines. 2. Install the engine oil cooler lines to the radiator. 3. Install air cleaner assembly. 4. Raise the vehicle. Page 4504 7. Install the NEW metal (copper) gaskets to the brake hope and the bolt. Notice: Refer to Brake Hose Installation Notice in Service Precautions. 8. Install the rear brake hose bolt. Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Brake Caliper Overhaul - Front (Single Piston) Brake Caliper Overhaul - Front (Single A Piston) Tools Required ^ J26267 Piston Seal Installer Disassembly Procedure 1. Drain all of the brake fluid from the caliper. 2. Install a piece of wood or shop towels between the caliper and the piston. 3. Cover the brake caliper with a shop rag. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 4. Apply only enough compressed air to the brake caliper to remove the piston. 5. Remove the shop rag cover from the brake caliper. 6. Remove the piece of wood or shop towels from the brake caliper. Page 8847 2. Position the step panel over the brackets using the following steps: 2.1. Slide the step panel over the support brackets. 2.2. Slide the step panel under the side outer panel. 3. Install the rear step panel to the side outer panel using the 4 push-pin fasteners. 4. Loosely install the 1 screw through the step panel into the forward support bracket. 5. Loosely install the 1 screw through the top of the step into the rear support bracket. 6. Tighten the following fasteners in the specified order while pushing the forward and rear support brackets upward. NOTE: Refer to Fastener Notice in Service Precautions. Tighten 1. Tighten the forward and rear support bracket stud nuts to 25 N.m (18.4 lb ft). 2. Tighten the step panel to support bracket screws to 9.0 N.m (6.6 lb ft). Service and Repair Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. - Tighten the backup lamp switch to 37 Nm (27 ft. lbs.). 2. Connect the backup lamp switch electrical connector. 3. Lower the vehicle. Page 3482 Steps 1 - 9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Page 2973 Connect the electrical connector for the solenoid to the connector on the new hose assembly. Connect the hose with the white nipple to the vacuum source hose. Connect the remaining hose to the shut off valve. Install the shield covering the AIR pump. Lower the vehicle. Remove the coolant reservoir nut nearest the battery. Route the new hose assembly between the battery and the coolant reservoir with the solenoid on top. Install the solenoid bracket onto the coolant reservoir stud and reinstall the nut back into the vehicle. Use a wire tie to keep the new hose assembly away from the engine. On four cylinder engines, tie to the AIR outlet hose. On six cylinder engines, tie to an available hole in the radiator fan shroud. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3245 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Page 1907 3. Install two new screws for the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identify the correct rotor mounting position: - At the rotor screw holes (1) - At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. Page 6819 IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor can no longer be properly mounted. 7. Perform the following steps in order to complete the first fastener repair: 7.1. Remove and discard the improperly installed rivet. 7.2. Reattach sensor with new rivet. 8. Perform the following steps in order to complete the second fastener repair: 8.1. Remove the improperly installed rivet. 8.2. Enlarge the mounting holes (1) in the lower radiator support to 9.0 mm (0.35 in). 8.3. Insert and properly seat the rivnut. 8.4. Install sensor with screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten fasteners to 8.0 N.m (71 lb in). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the inflatable restraint front end discriminating sensor horizontally to the lower radiator support surface. Ensure that the arrow is pointing toward the front of the vehicle. 3. Install the inflatable restraint front end discriminating sensor mounting rivets (GM P/N 15715058). Page 7690 Abbreviations And Meanings - Part 18 Page 9120 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 9203 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 5927 8. Install the new nut to the relay rod ball stud at the pitman arm. Tighten the relay rod ball stud nut at the pitman arm to 48 Nm (36 ft. lbs.). 9. Install the inner tie rod ball studs to the relay rod. Ensure that the seal is on the stud. 10. Seat the taper using J 29193 or J 29194. Tighten J 29193 or J 29194 to 54 Nm (40 ft. lbs.). 11. Remove J 29193 or J 29194 from relay rod ball stud. Repeat steps 10 and 11 for opposite inner tie rod to relay rod. 12. Install the new nuts to the inner tie rod ball studs. Tighten the inner tie rod ball studs nuts to 47 Nm (35 ft. lbs.). 13. Lower the vehicle. 14. Adjust the front toe. Page 8850 5. Remove the filler plate. 6. Remove the forward brace from the step panel and the forward support bracket. 7. Remove the screw that secures the step panel to the pickup box rear inner pillar. Page 5707 C430 (Chassis Harness To License Lamp Harness) (Export) Page 9534 Registered And Non-Registered Trademarks - Part 3 Page 2622 Steps 12-15 Page 4070 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 3408 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. 3. Install the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clean and free of burrs. 4. Install the CKP sensor mounting bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). 5. Connect the CKP sensor harness connector. Page 94 Memory Seat Module - Driver C1 Part 3 Memory Seat Module - Driver C2 Part 1 Locations Seat Switches Page 8344 WA820K/94 - WA8554/40 Page 8679 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. - After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 809 Abbreviations And Meanings - Part 18 Page 8407 Memory Seat Module - Driver C1 Part 3 Memory Seat Module - Driver C2 Part 1 A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Specifications Piston Pin: Specifications Piston Pin Pin - Piston Pin Clearance to Connecting Rod Bore - Press Fit ........................................................................ 0.012 - 0.048 mm (0.0005 - 0.0019 inch) Pin - Piston Pin Clearance to Piston Pin Bore - Production .............................................................................. 0.013 - 0.023 mm (0.0005 - 0.0009 inch) Pin - Piston Pin Clearance to Piston Pin Bore - Service .............................................................................................................. 0.025 mm (0.0010 inch) Pin Piston Pin Diameter .............................................................................................................................. 23.545 - 23.548 mm (0.9270 - 0.9271 inch) Page 7435 Page 5839 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 7858 Rear Door Latch: Service and Repair Latch Replacement - Side Door Upper Latch Replacement - Side Door Upper Removal Procedure 1. Remove the door trim panel. 2. Disconnect the latch rod (3) from the retainer on the latch control handle. 3. Remove the upper latch bolt (4). 4. Remove the anti-rotation screw (5). 5. Remove the wedge (6) from the door. Page 3310 14. Remove the round washer. 15. Remove the tang washer. 16. Remove the shim washer (1). 17. Remove the old oil seal. ASSEMBLY PROCEDURE 1. Line up the square-cut hole in the vane wheel for the CMP sensor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. 2. Insert the sensor into the housing. Page 4375 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the electrical connector from the sensor. 4. Remove the bolt (2). 5. Using a twisting and pulling motion, remove the vehicle speed sensor (1) from the case. 6. Remove and discard the O-ring seal (3). Installation Procedure 1. Install the new O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with clean transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Remove the drain pan. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 903 3. Tighten the air cleaner cover wingnuts. Page 4374 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 6844 Air Bag Control Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Page 2693 Abbreviations And Meanings - Part 13 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1005 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover wingnuts. 2. Remove the air cleaner cover. 3. Remove the air cleaner element. 4. Clear out any debris in the air cleaner housing. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner housing. 2. Install the air cleaner cover. Page 4919 Abbreviations And Meanings - Part 19 Page 4831 8. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Page 3697 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 523 Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 4725 11. Remove the park brake cable from the park brake actuator. 12. Using the J37043 (1), collapse the locking tabs on the park brake cable. 13. Remove the J37043 (1) from the park brake cable. 14. Remove the park brake cable from the rear brake cable bracket. Installation Procedure Important: When installing the park brake cable in any of the retainers, ensure that the locking tabs on the park brake cable are fully seated against the retainer. Page 275 2. Connect the electrical connector to the switch. 3. Install the trim panel to the seat with the 3 screws. 4. Install the seat to the vehicle. Page 9024 Audible Warnings Diagram 4 Page 4234 1. Install the shift tower housing to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shift tower housing bolts. ^ Tighten the shift tower housing bolts to 20 Nm (15 ft. lbs.). 3. Install the boot to the shift tower. 4. Install the shift boot screws. ^ Tighten the shift boot screws to 2 Nm (18 inch lbs.). 5. Install the shift lever to the shift tower. Control Lever and/or Boot Replacement Control Lever and/or Boot Replacement Removal Procedure Locations Relay Block - Body Relays, Except Envoy Page 8784 2. Keeping the position lock pin on the new SOP switch, align the switch over the drive cables. IMPORTANT: The SOP switch comes from the factory with a position lock pin that is installed on top of the switch. This locks the timing gears in place. Do not remove the position lock pin until after the SOP switch and the actuator are installed. 3. Apply pressure to the SOP switch until the switch is completely seated. If the switch does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOP switch. Lift each cable into the switch, and press down on the assembly until the assembly is completely seated. 4. Install the screw which secures the SOP switch to the sunroof module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 3.4 N.m (30 lb in). 5. Connect the electrical connector to the SOP switch. 6. Install the sunroof motor/actuator. 7. Remove the position lock pin (1). 8. Remove the 2 alignment pins from the cable mechanisms and/or from the cam mechanisms. 9. Install the sunroof control module, but do not install the headliner until after the sunroof operation has been verified. 10. Verify the operation of the sunroof module. 11. Install the sunroof window. 12. Install the headliner. Page 256 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (w/ 6-Way) Part 1 Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 379-427 kPa (55-62 psi) Page 3141 Steps 18-23 Page 5602 Fuse Block - Underhood Connector C4 Part 4 Specifications Console: Specifications Fastener Tightening Specifications Page 9491 Equivalent - Decimal And Metric Part 1 Page 2366 Page 9572 Page 8540 1. Slide the memory seat module into the bracket until the module is seated. 2. Install the memory seat module and bracket to the seat adjuster frame assembly with 2 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the memory seat module retaining screws to 3 N.m (26 lb in). 3. Install the memory seat module harness connectors. 4. Install the front seat to the vehicle. Page 261 Seat Adjuster Switch - Front Passenger C1 (w/ 8-Way, w/o Memory) Part 2 Page 160 Body Control Module (BCM) C2 Part 2 Page 9073 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5690 C302 (Power Seat Harness, LH To Power Recliner Harness, LH) (w/ Power Seats, Memory) Page 3219 5. Install the accelerator cable routing bracket using the mounting nuts. Tighten Tighten the accelerator cable routing bracket nuts to 9 N.m (80 lb in). 6. Install the accelerator cable onto the throttle body. NOTE: Also check for poor carpet fit under the accelerator pedal. Throttle should operate freely without bind between full closed and wide open throttle. 7. Install the cruise control cable onto the throttle body. Page 2335 7. Align the square slot in the reluctor wheel with the CMP sensor. 8. Remove the CMP screws. 9. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: DO NOT use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. Page 4562 5. Install the brake caliper. 6. Burnish replaced or refinished rotors. Page 9013 Abbreviations And Meanings - Part 25 Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration , to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 7144 Driver/Vehicle Information Display: Electrical Diagrams Driver Information System Diagram 1 Page 9999 Rear Wiper/Washer And Endgate Window Release Switch Page 2591 Powertrain Control Module (PCM) Connector C1 Part 4 Page 5026 Abbreviations And Meanings - Part 15 Page 2684 Abbreviations And Meanings - Part 4 Page 1825 Use a hammer and the J 46165 Pin Driver to install the dowel pins through the two lower holes in the bracket and into the engine block. Make sure that the bracket is held firmly in place before proceeding. For model years 1996-1998, install a roller-type timing chain set. Install the crankshaft sprocket using the J 5590 Crankshaft Gear Installer. Install the timing chain around the crankshaft sprocket and position the timing chain to the driver's side of the engine. Install the nylon timing chain tensioner guide onto the timing chain tensioner bracket pin and position the top of the guide under the tab at the top of the bracket. Install the camshaft sprocket into the chain and then to the camshaft. Install the bolts finger-tight. Make sure the timing marks are aligned, then tighten the camshaft sprocket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Install the crankshaft reluctor ring. Install the engine front cover and place a washer under the two center cover bolts that extend through the tensioner bracket. These washers are required to maintain the proper crush on the engine front cover seal. Tighten Page 1463 hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: - The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Specifications Radiator Hose: Specifications Radiator Inlet Hose Support Bracket Nut to Exhaust Manifold Stud ....................................................................................................... 36 Nm (27 ft. lbs.) Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 4028 Left Side Control Valve Body Assembly Page 2041 Heater Core: Service and Repair Heater Core Replacement Removal Procedure 1. Remove the heater/vent module. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the heater core access cover screws. 3. Remove the heater core access cover. 4. Remove the heater core from the heater/vent module. Installation Procedure Page 8396 WA9260/74 - WA9539/47 Locations Electronic Components Page 1752 Important: Do not discharge the refrigerant. 24. Perform the following in order to remove the left front bolt for the intake manifold: 24.1. Remove the drive belt. 24.2. Loosen the nut for the power steering pump rear bracket at the side of the engine. 24.3. Remove the nut for the power steering pump rear bracket at the front of the engine. 24.4. Remove the bolts and the nut for the power steering pump mounting bracket. 24.5. Leave the A/C compressor, if equipped, and the power steering pump on the power steering pump mounting bracket. 24.6. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold. 25. Remove the Engine Coolant Temperature (ECT) sensor wire connector (if equipped) from the engine wiring harness bracket. 26. Remove the lower intake manifold bolts. Important: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required. Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless service is required. 27. Remove the intake manifold assembly. 28. Remove and discard the lower intake manifold gaskets. Important: Do not immerse the assembled intake manifold in cleaning solvent. Page 6802 Inflatable Restraint Steering Wheel Module Coil C2 (Pigtail To The Body Harness) Locations Electronic Components Page 9039 16. Install the new compass mounting bracket. 17. Install the compass mounting bracket screw. Tighten Tighten the screw to 1.9 N.m (17 lb in). 18. Connect the console electrical connectors. 19. Insert the console mounting tabs into the mounting bracket and push upward on the rear of the console in order to install the console. 20. Install the screw at the front of the console. Tighten Tighten the screw to 1.9 N.m (17 lb in). 21. Calibrate the compass. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Cross-Member: Service and Repair Transmission Support Replacement (RWD) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Install the transmission jack to the transmission and support the transmission. 3. Disconnect the transmission wiring harness from the transmission support, if necessary. 4. Remove the transmission mount to the transmission support stud nut, 2.2 L. 5. Remove the transmission mount to the transmission support stud nut, 4.3 L pickup and utilities. 6. Remove the catalytic converter hanger bracket from the transmission support mounting bolts, 2.2 L if necessary. Page 2779 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. 1. Remove the left instrument panel sound insulator from the vehicle. 2. Remove the lower instrument panel sound insulator from the vehicle. 3. Disconnect the electrical connectors from the body control module. 4. Bend the 2 snap retainers back slightly and pull the body control module from the bracket at an angle. INSTALLATION PROCEDURE 1. Install the body control module to the bracket at an angle under the wide hook retainer, with the label facing away from the bracket. 2. Apply pressure on the left side of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 3. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. 4. Connect the electrical connectors to the body control module. Be sure to connect the brown connector last. 5. Install the lower instrument panel sound insulator to the vehicle. 6. Install the left instrument panel sound insulator to the vehicle. 7. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The scan tool 8. Perform the BCM Programming. See: Testing and Inspection/Programming and Relearning 9. Clear the diagnostic trouble codes (DTCs). Page 9811 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 4499 Important: When performing the following service procedure, DO NOT reuse the washers, replace them with new washers. 8. Install the front brake hose fitting, the 2 new gaskets and the brake hose fitting bolt. Tighten the front brake hose bolt to 54 Nm(40 ft. lbs.). 9. Fill the brake master cylinder to the proper level. 10. Bleed the brake caliper. 11. Inspect the brake system for leaks. 12. Install the tire and wheel assembly. 13. Lower the vehicle. Refer to Vehicle Lifting. Brake Caliper Replacement - Front (Dual Piston) Brake Caliper Replacement - Front (Dual Piston) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper hose bolt from the brake caliper. 4. Remove the 2 copper gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 5. Discard the 2 copper gaskets. 6. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 7. Remove the brake hose and washers from the brake caliper. Page 7238 Page 3936 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7664 Conversion English/Metric Part 2 Page 766 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 583 Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, And Positive Crankcase Ventilation (PCV) Valve Page 2370 Crankshaft Position (CKP) Sensor Page 4500 8. Remove the brake caliper guide pin bolts. 9. Remove the brake caliper assembly. Installation Procedure 1. Install the brake caliper on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 8352 WA8624/50 - WA882K/90 Page 5197 Relay Block - Body Part 7 Page 3868 Electronic Components Page 6846 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and SIR Disabling and Enabling Zone 3. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the floor console, if equipped. 3. Cut an "X" in the carpet over the inflatable restraint sensing and diagnostic module (SDM). 4. Fold the carpet back to expose the SDM. 5. Remove the connector position assurance (CPA) (4) from the SDM harness connector (3). 6. Disconnect the SDM harness connector (3) from the SDM (2). 7. Remove the SDM mounting fasteners (1). 8. Remove the SDM (2) from the vehicle. 9. Repair the fasteners using the following procedure: IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 9.1. Remove the stripped nut and discard the nut. 9.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 9.3. Condition the floor panel attaching surface where the new stud is to be installed. 9.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 9.5. Migweld the stud at the drilled holes from above or below the floor pan (as required). 9.6. Apply body sealer GM P/N 9984248 around any exposed openings. 9.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Page 6084 Abbreviations And Meanings - Part 7 Page 8926 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector. 4. Remove the 3 nuts that retain the cruise control module to the mounting bracket studs. 5. Remove the cruise control module from the mounting bracket. 6. Remove the 3 screws that retain the mounting bracket to the cowl panel. INSTALLATION PROCEDURE 1. Install the mounting bracket to the cowl panel with the 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cruise control module bracket screws to 4.5 N.m (40 lb in). 2. Install the cruise control module to the vehicle. 3. Install the 3 nuts that retain the cruise control module to the mounting bracket. Page 691 Fluid Pressure Sensor/Switch: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 4843 6. Remove the nut retaining the positive battery cable to the starter. 7. Remove the positive battery cable bolt from the engine. 8. Remove the battery positive cable. INSTALLATION PROCEDURE 1. Install the positive battery cable to the vehicle. 2. Install the positive battery cable nut to the engine. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the positive battery cable nut to 6 N.m (80 lb in). 3. Install the nut retaining the positive battery cable to the starter. Tighten Tighten the positive battery cable nut to 9 N.m (80 lb in). 4. Lower the vehicle. Page 8430 Luggage Rack: Service and Repair Luggage Carrier Rivnut Replacement Luggage Carrier Rivnut Replacement Removal Procedure 1. Remove the luggage carrier. Caution: Refer to Safety Glasses Caution in Service Precautions. 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Use a 10 mm (0.39 in) drill bit to drill the hole in the roof out. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. NV 1500 Transmission Speed Sensor: Service and Repair NV 1500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the vehicle speed sensor electrical connector. 3. Remove the vehicle speed sensor retaining bolt. 4. Remove the vehicle speed sensor. Installation Procedure 1. Install the new O-ring seal to the vehicle speed sensor. 2. Coat the new O-ring seal with a thin film of transmission fluid. 3. Install the vehicle speed sensor Notice: Refer to Fastener Notice in Service Precautions. 4. Install the vehicle speed sensor retaining bolt. ^ Tighten the vehicle speed sensor retaining bolt to 16 Nm (12 ft. lbs.). 5. Connect the vehicle speed sensor electrical connector. 6. Lower the vehicle. Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch - Driver (Utility, Crew Cab W/ RKE) Page 6010 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 7116 Abbreviations And Meanings - Part 9 Page 8365 WA253A/86 - WA379E/86 Page 5097 Arrows And Symbols Uses various symbols in order to describe different service operations Page 1644 2. Install the engine mount and shield to the engine. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine mount to engine bolts. Tighten the engine mount to engine bolts to 54 Nm (40 ft. lbs.). 4. install the engine mount frame bracket to the frame. 5. Install the engine mount frame bracket bolts. Tighten the engine mount frame bracket bolts to 45 Nm (33 ft. lbs.). 6. Lower the engine and remove the jack. 7. Install the engine mount through-bolts and nuts. Tighten the through-bolts or the nuts to the following: ^ Tighten the through-bolts to 74 Nm (55 ft. lbs.). ^ Tighten the nuts to 63 Nm (46 ft. lbs.). Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door Tools Required J 34940 Rivet Gun Removal Procedure Important: The rear door power window motor and regulator replacement parts are sold as an assembly. Do not attempt to separate the motor from the regulator before verifying that separate replacement parts are available. 1. Remove the window. 2. Disconnect the power window motor electrical connector, if equipped. 3. Remove the electrical harness retainers, if equipped. 4. Drill out the rivets that secure the window regulator to the door. 5. Remove the window regulator and the motor assembly (power windows only) from the door. Installation Procedure 1. Install the window regulator and the motor assembly (power windows only) to the door. 2. Install the rivets that secure the window regulator to the door using J 34940. 3. Install the electrical harness retainers, if equipped. 4. Install the power window motor electrical connector, if equipped. 5. Install the window. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front .................................................................................................................................................... ..................................................................... 2.6 Pints Rear ................................................................ .......................................................................................................................................................... 4.0 Pints Page 9989 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mounting screws. Tighten Tighten the wiper transmission mounting screws to 8 N.m (70 lb in). IMPORTANT: Lubricate the inside of the socket with white lithium grease (GM P/N 9985885) or equivalent. - The wiper transmission must be assembled to the crank arm past the second detent so the seal is compressed to a maximum height of 25.5 mm (1 in). 1. Install the transmission drive link to the wiper motor crank arm using the J 39529. 2. Install the air inlet grille panel. 3. Install the wiper arms. Page 8971 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Page 8068 Tighten the transmission mount to the transmission support stud nut to 45 N.m (33 lb ft). 9. Connect the transmission wiring harness to the transmission support, if necessary. 10. Remove the transmission jack from the transmission. 11. Lower the vehicle. Page 943 9. Install the distributor cap. 10. Install two new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. 13. Install the ignition coil wire. Note the correct orientation of the wire boot. 14. Refer to installation procedure 2 if malfunction indicator lamp is turned ON after installing the distributor. IMPORTANT: If the malfunction indicator lamp (MIL) is turned ON after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly. INSTALLATION PROCEDURE 2 Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Page 507 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 9524 Abbreviations And Meanings - Part 20 Page 1476 ^ Crankshaft sprocket keyway for wear Installation Procedure 1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline. 2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key. 3. Use the J 5590 in order to install the crankshaft sprocket. Important: Install the camshaft sprocket with the alignment mark at the 6 o'clock position. 4. Install the camshaft sprocket and the camshaft timing chain. Page 7821 2. Remove the bolts retaining the striker to roof panel. 3. Remove the striker and shim(s) from the roof panel. Installation Procedure Page 190 4. Slide the PCM retainer into the PCM bracket slots. 5. Pull the PCM retention bar into position. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release throttle when fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release when the fuel cut-off occurs. 8. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. 3. Test the circuit operation. Page 3608 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 9682 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 5772 C413 (Engate Harness To Body Harness) Page 9593 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 5526 Abbreviations And Meanings - Part 5 Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Fuse Block - Underhood Location View Page 9801 Equivalent - Decimal And Metric Part 1 Page 3817 Seals and Gaskets: Service and Repair Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. If the vehicle is equipped with a 2.2L engine, remove the bolt securing the dipstick to the exhaust manifold. 2. Remove the transmission oil level indicator. 3. Raise the vehicle. 4. If the vehicle is equipped with a 2.2L engine, proceed to step 7. 5. If the vehicle is equipped with a 4.3L engine, remove the exhaust manifold pipe 6. Remove the rear propeller shaft. 7. Support the transmission and transfer case, if equipped, with a suitable jack. 8. Remove the transmission support. Page 8363 Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Page 571 Automatic Transmission, RH Page 4984 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 4463 Brake Bleeding: Service and Repair Manual Bleeding Procedure Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 2889 Intake Air Temperature Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. Intake Air Temperature (IAT) Sensor 3. Remove the IAT sensor by pulling straight out using a rotating motion. INSTALLATION PROCEDURE NV 1500 Vehicle Speed Sensor Page 4497 6. Compress the front caliper piston. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the piston is fully seated in the brake caliper bore. ^ Remove the C-clamp from the caliper. 7. Remove the brake caliper hose bolt from the brake caliper. 8. Remove the 2 metal gaskets from the brake caliper bolt. These gaskets maybe stuck to the brake caliper and/or the brake hose end. 9. Discard the 2 metal gaskets. 10. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. 11. Remove the brake caliper mounting bolts. 12. Remove the brake caliper. 13. Remove the brake pads from the brake caliper. Page 2143 Powertrain Control Module (PCM) Page 9637 Abbreviations And Meanings - Part 18 Page 1097 Coolant: Fluid Type Specifications Engine Coolant 50/50 mixture of clean, drinkable water and use only GM Goodwrench DEX-COOL or Havoline DEX-COOL Coolant. Page 4983 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 518 Intake Air Temperature (IAT) Sensor 1. Install the IAT sensor by gently pushing the sensor into the air cleaner outlet duct until seated. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Page 1602 8. Use the J 5892-D in order to compress the valve spring. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9. Apply steady pressure on the valve spring cap until the valve keys are accessible. Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use the J 38606 if the clearance does not permit use of the J 5892-D. 11. Install the valve stem O-ring seal. 12. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 13. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 14. Remove the J 5892-D or the J 38606. 14.1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 14.2. Tap the end of the valve stem with a plastic faced hammer in order to seat the valve stem keys, if necessary. Wheel Speed Sensor (WSS) - LF Page 8944 Locations Clutch Switch: Locations Instrument Panel, LF Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. - After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 1223 Fuse Block - Underhood Connector C3 Part 2 Page 6780 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 9630 Abbreviations And Meanings - Part 11 Page 8121 1. Install the console to the roof. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the overhead console to the roof with the three roof screws. Tighten the overhead console screws to 2 N.m (18 lb in). Console Replacement - Overhead (Short Length) Console Replacement - Overhead (Short) Removal Procedure 1. Remove the console roof screw. 2. Disconnect the electrical connectors. 3. Remove the console. Installation Procedure 1. Install the console to the roof. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the console roof screw. Tighten the overhead console screw to 2 N.m (18 lb in). Cupholder Replacement - Front Floor Console CUPHOLDER REPLACEMENT - FRONT FLOOR CONSOLE REMOVAL PROCEDURE Page 6535 Body Wiring To Blower Motor And Resistor (With RPO Code RPO C60) Page 3714 Disclaimer Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Wheel Speed Sensor Replacement (RWD Pickup) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor cable electrical connector (2). 6. Remove 13 mm bolt and nut fastening the wheel speed sensor harness clip to the front side of the upper control arm. 7. Remove clips from the wheel speed sensor wire. Save the clips for the sensor wire. 8. Remove two 13 mm wheel speed sensor mounting bolts (7). 9. Remove two 11 mm splash shield mounting bolts. 10. Remove wheel speed sensor and splash shield assembly (6). 11. Remove splash shield gasket. 12. Clean gasket and knuckle surfaces thoroughly with a dry cloth. Installation Procedure 1. Install splash shield gasket. 2. Install wheel speed sensor and splash shield assembly (6). Notice: Refer to Fastener Notice in Service Precautions. 3. Install two 11 mm splash shield mounting bolts. ^ Tighten the splash shield mounting bolts to 16 Nm (12 ft. lbs.). ^ Tighten the speed sensor mounting bolts (7) to 26 Nm (119 ft. lbs.). 4. Install harness clips to the wheel speed sensor wire. Page 529 4. Install the distributor. 5. Connect the negative battery cable. Page 6095 Abbreviations And Meanings - Part 18 Page 5903 centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Page 7666 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 5473 Page 7251 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 4925 Abbreviations And Meanings - Part 25 Bed Rail Protector Replacement Truck Bed: Service and Repair Bed Rail Protector Replacement BED RAIL PROTECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the body plugs. 2. Remove bolts. 3. Remove bed rail protector. 4. Remove bed rail protector gaskets. INSTALLATION PROCEDURE 1. Install bed rail protector gaskets. 2. Install bed rail protector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install bolts and pressure plates. Tighten Tighten the bolt to 6.8 N.m (60.2 lb in). 4. Install the body plugs. A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 5761 C306 (Body Harness To RR Door Harness) (4-Door) Page 7818 Front Door Striker: Service and Repair Striker Replacement - Lower Striker Replacement - Lower Removal Procedure 1. Open the side access door 2. Remove the bolts retaining the lower door striker. 3. Remove the lower door striker. Installation Procedure Page 6498 English Prevailing Torque Fastener Minimum Torque Development Part 2 NYLON INTERFACE PREVAILING TORQUE FASTENERS Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth. Page 5095 Equivalent - Decimal And Metric Part 2 Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 7129 Abbreviations And Meanings - Part 22 Locations Electronic Components Page 6860 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. OnStar(R) - Number Incorrect/Incorrectly Assigned Cellular Phone: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 479 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 960 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8 - 11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8 - 11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 3653 Disclaimer Burnishing Pads and Rotors Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal Injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km1h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 692 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 3330 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner assembly (2) and nut (1). 2. Disconnect the electrical connectors. 3. Remove the ignition coil wire to the distributor. 4. Remove the accelerator cable bracket. 5. Remove the studs holding the bracket and the ignition coil to the intake manifold. 6. Remove the bracket and the ignition coil. Coolant Heater Engine Block Heater: Service and Repair Coolant Heater Coolant Heater Replacement (4.3L) Removal Procedure 1. Drain the cooling system. 2. Remove the coolant jacket plug, if not originally equipped with an engine coolant heater, by using the following procedure: 2.1. Carefully tap the coolant jacket plug near the outer edge. This causes the plug to rotate in the hole. Do not score the machined surface of the hole. 2.2. Grasp the plug with pliers and pull the plug out. 3. Remove the cord from the engine coolant heater. 4. Loosen the bolt. 5. Remove the engine coolant heater. 6. Clean the core plug hole. Remove any the following conditions: ^ Burrs ^ Compound ^ Paint ^ Rough spots Installation Procedure 1. Apply a coating of lubricant to the O-ring seal and the cleaned surface of the plug opening in the block. Use a water spray resistant, high-temperature grease lubricant (GM P/N 9985164 or equivalent). Important: Install the heater element. Avoid element contact to the inner walls of the engine block. 2. Install the engine coolant heater and push tight to the block. Notice: Refer to Fastener Notice in Service Precautions. Page 5483 Page 629 Manual, please make a reference to this bulletin on the affected page. Circuit Description The crankshaft position (CKP) sensor signal indicates the crankshaft speed and position. The CKP sensor circuits are connected directly to the powertrain control module (PCM) and consists of the following circuits: ^ The 12-volt reference circuit ^ The low reference circuit ^ The CKP sensor signal circuit If the PCM detects that the CKP sensor signal is inconsistent for 2 seconds, DTC P0336 sets. Conditions for Running the DTC The engine is cranking or running. Conditions for Setting the DTC The PCM detects that the CKP sensor signal is inconsistent for 2 seconds. Action Taken When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL and the DTC with a scan tool. Disclaimer Page 2571 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE IMPORTANT: When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. - DO NOT reuse the original O-ring. 1. Replace the CKP sensor O-ring. Page 5399 6. Loosen the bolts that secure the electrical connectors to the bottom of the underhood electrical center. 7. Disconnect the electrical connectors from the underhood electrical center. 8. Remove the underhood electrical center from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the underhood electrical center. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the electrical connector to the underhood electrical center bolts to 7 N.m (62 lb in). Page 7527 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 3001 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) vapor pipe from the fuel sender assembly. 3. Cap the fuel sender and EVAP vapor pipe in order to prevent contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel sender assembly and EVAP vapor pipe. 2. Connect the EVAP vapor pipe to the fuel sender assembly. 3. Install the fuel tank. Page 1160 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ......................................................................................................................................... Polyalkaline Glycol (PAG) Refrigerant Oil Page 4232 1. Install the shift housing to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 bolts securing the shift housing to the transmission. ^ Tighten the shift housing bolts to 20 Nm (15 ft. lbs.). 3. Install the screws securing the boot to the panel. ^ Tighten the screws to 2 Nm (18 inch lbs.). 4. Install the shift lever to the Shift tower housing. 5. Install the console and the 3 console nuts (If equipped). ^ Tighten the nuts to 2 Nm (18 inch lbs.). Page 4860 Page 1988 Engine Coolant Temperature (ECT) Sensor Page 3191 NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the IAC valve are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 3 N.m (27 lb in). 6. Connect the IAC valve harness connector. 7. Install the air cleaner outlet resonator. 8. Perform the IAC Reset procedure: 8.1. Turn ON the ignition, with the engine OFF, for 5 seconds. 8.2. Turn OFF the ignition for 10 seconds. 8.3. Start the engine and check for proper idle speed. Locations Endgate Harness Routing View Locations Sunroof / Moonroof Motor: Locations Sunroof Control Module And Motor Locations Electronic Components Page 9022 Audible Warnings Diagram 2 Page 5290 C412 (Endgate Harness To Body Harness) Page 1790 Engine Harness Rear (4.3L) Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4230 1. Install the boot over the shift tower. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shift boot screws. ^ Tighten the screws to 2 Nm (18 inch lbs.). 3. Install the shift lever to the shift tower. If required, center the shift lever with the adjusting nut. ^ Tighten the adjusting nut to 48 Nm (35 ft. lbs.). 4. If equipped Install the console and the 3 console nuts. ^ Tighten the nuts to 2 Nm (18 inch lbs.). Shift Tower Replacement Shift Tower Replacement Removal Procedure Page 8852 1. Loosely install the rear support bracket onto the cross sill studs using the 2 nuts and 1 screw through the rear pillar assembly. 2. Loosely install the forward bracket onto the pickup box cross sill studs using the 2 nuts. 3. Position the step panel over the brackets using the following steps: 3.1. Slide the rear inboard tab around the rear pillar assembly. 3.2. Slide the step panel under the side outer panel. 4. Install the rear step panel to the side outer panel using the 4 push-pin fasteners. 5. Loosely install the 1 screw through the forward bracket into the step panel. 6. Loosely install the 3 screws through the top of the step into the rear support bracket. 7. Tighten the following fasteners in the specified order while pushing the forward and rear support brackets upward. NOTE: Refer to Fastener Notice in Service Precautions. Tighten 1. Tighten the rear pillar to rear support bracket screw to 9.0 N.m (6.6 lb ft). 2. Tighten the forward support bracket to step panel screw to 9.0 N.m (6.6 lb ft). 3. Tighten the forward and rear support bracket stud nuts to 25 N.m (18.4 lb ft). Page 2515 Camshaft Position (CMP) Sensor A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 6074 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 5225 For vehicles repaired under warranty, use the table. Disclaimer Page 2266 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 8574 Seat Adjuster Switch - Driver/Front Passenger (w/ Memory) Part 2 Service and Repair Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the A/C pressure switch (4.3L only). 3. Remove the accumulator (2) to evaporator nut. 4. Remove the compressor hose assembly from the accumulator. 5. Remove the O-ring seals and discard. 6. Remove the accumulator clamp bolt. 7. Remove the accumulator. Page 1510 Balance Shaft: Service and Repair Balance Shaft Replacement ^ Tools Required J 8092 Universal Driver Handle - J 36660-A Electronic Torque Angle Meter - J 36996 Balance Shaft Installer Removal Procedure 1. Remove the radiator. 2. Remove the A/C condenser. 3. Remove the valve lifter pushrod guide. 4. Remove the timing chain and camshaft sprockets. 5. Remove the balance shaft drive gear. Important: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt. 6. Remove the balance shaft driven gear bolt from the balance shaft. 6.1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Remove the balance shaft bolt. 6.3. Remove the wrench from the balance shaft. 7. Remove the balance shaft driven gear from the balance shaft. Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Page 5236 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 1 Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Removal Procedure Caution: Always use double-walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and in the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and brake system resulting in personal injury. Important: Brake pipes that run parallel to each other must maintain a 6 mm (1/4 lbs.) clearance. 1. Disconnect the brake pipe fittings. 2. Remove the brake pipe fasteners from the vehicle. 3. Remove the brake pipe from the vehicle. Installation Procedure 1. Bend the brake pipe to achieve proper fit. 2. Install the brake pipe to the vehicle. Maintain a clearance of 19 mm (3/4 lbs.) for all moving or vibrating components. 3. Install the brake pipe fasteners to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the brake pipe fittings. ^ Tighten the brake pipe fittings to the BPMV or the wheel jounce hoses to 20 Nm (15 ft. lbs.). ^ Tighten the brake pipe fittings to the master cylinder to 30 Nm (22 ft. lbs.). 5. Bleed the brake hydraulic system. Refer to one of the following procedures: ^ If the brake pipe that was replaced was between the master cylinder and the BPMV, refer to ABS Automated Bleed Procedure. ^ If the brake pipe that was replaced was between the BPMV and the wheel jounce hoses, refer to Hydraulic Brake System Bleeding. Page 5366 C500 (Body Harness To LF Door Harness) (W/O Power Locks/Windows) Page 5794 Splice Pack SP202 Page 9908 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Remove the side rear door trim panel. 2. Remove the staples that secure the sealing strip to the trim panel. 3. Remove the sealing strip. Installation Procedure 1. Position the sealing strip on the trim panel. 2. Install the sealing strip to the trim panel using the original staples or a heavy-duty staple gun. 3. Install the side rear door trim panel. Page 4538 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Page 4225 2. Install the following parts: 2.1. The O-ring on the vehicle speed sensor assembly. 2.2. The vehicle speed sensor assembly. 2.3. Tighten Tighten the bolt to 16 Nm (12 ft. lbs.). 3. Install the electrical connector to the vehicle speed sensor. 4. Lower the vehicle. Page 5720 C109 (Body Harness To The 4WAL/SIR Harness) Page 8623 14. Install the trim plate. 15. Install the seat to the vehicle. Page 5718 C108 - Active Transfer Case Extension Harness To Body Harness, NP8 Part 2 Page 8988 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 9155 Driver/Vehicle Information Display: Connector Views Driver Information Center (DIC) C1 (w/ Trip Computer) Part 1 Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Service and Repair Ground Strap: Service and Repair REMOVAL PROCEDURE Additional ground straps are used to connect the body and the frame to the engine and the transmission. Always connect all ground straps in order to ensure a good ground path to the battery for all electrical components. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the ground strap bolt from the engine. 3. Lower the vehicle. 4. Remove the ground strap bolt from the cowl. 5. Remove the ground strap. INSTALLATION PROCEDURE Page 4484 16. Discard the rubber O-rings. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent. 2. Dry the brake caliper pin bolts using non-lubricated, compressed filter air. 3. Lubricate the sleeves and bushings with Delco Silicone Lube, GM P/N 18010909, or equivalent. 4. Install the rubber O-ring bushings to the brake caliper. 5. Install the brake caliper mounting bolt sleeves. 6. Install the brake pads to the brake caliper. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the brake caliper mounting bolts. Tighten the brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Notice: Refer to Brake Hose Installation Notice in Service Precautions. Important: When performing the following service procedure, DO NOT reuse the washers, replace them with new washers. Page 8594 10. Remove the 2 bolts (1) from the seat back pivot assembly. 11. Remove the cable cover bracket (2). 12. Remove the cable (3) from the bracket (1) by loosening cable nut (2). 13. Remove cable (3). INSTALLATION PROCEDURE 1. Install the cable (3) through the hole (2) in the seat adjuster rail. 2. Hook the cable (3) into the rail and clip the cable to the rail (1). Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Use the J 38778 in order to remove the door auxiliary weatherstrip from the vehicle. Installation Procedure 1. Install the door auxiliary weatherstrip to the vehicle. 2. Position the weatherstrip and press the weatherstrip into place. Ensure that the retaining clips lock into place. Page 9480 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Body Opening Frame, Rear Window Defogger, Exterior Harness Body Opening Frame, Rear Window Defogger, Exterior Harness Page 8230 Door Lock Cylinder Switch - Driver (Utility W/ Content Theft) Page 5243 C119 (4WAL/SIR Harness To AIR Jumper Harness) Page 8942 Page 8114 5. Remove the transmission select switch (if equipped). 6. Remove the nuts that retain the rear of the console. 7. Remove the cup holder insert. 8. Remove the screws that retain the front of the console to the vehicle. 9. Remove the console from the vehicle. INSTALLATION PROCEDURE Page 7058 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 9378 Conversion English/Metric Part 1 Page 7903 Tighten the bolt to 25 N.m (18 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2367 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 9552 Steps 11-16 Page 5355 C403 (Body Harness To LH Tail Lamp Harness) (Export) Page 9805 Conversion English/Metric Part 1 Page 2785 Powertrain Control Module (PCM) Page 1167 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 lbs.), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 5121 Abbreviations And Meanings - Part 14 Speaker - LF Speaker - LF (Utility) OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 2563 This bulletin is being issued to revise DTC P0336 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Page 6895 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Rear REMOVAL PROCEDURE 1. Fold the rear seats forward. Lift the rear seat floor filler trim panels to access the rear seat belt buckle assembly. 2. Remove the rear seat belt buckle assembly retaining nuts. 3. Remove the rear seat belt buckle assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the rear seat belt buckle assembly to the vehicle. 2. Install the rear seat belt buckle assembly retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt buckle assembly retaining nuts to 42 N.m (31 lb ft). Page 5634 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 6496 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 235 Door Lock Cylinder Switch - Driver (Utility W/ Content Theft) Page 3438 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 8690 Abbreviations And Meanings - Part 10 Page 841 Rear Wiper/Washer And Endgate Window Release Switch Page 6218 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage Page 4331 ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 460 Engine Coolant Temperature (ECT) Sensor Page 2288 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE 1. Raise the vehicle. CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 5645 C101 (Body Harness To Engine Harness) Part 2 Page 6424 Air Temperature Actuator Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement ^ Tools Required J 23742 Ball Joint Separator - J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer Removal Procedure Caution: Refer to Floor Jack Caution in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. ^ Support the lower control arm with floor stands. ^ Place floor stands under the lower control arms as far outboard as possible (between spring seats and ball joint) to maintain maximum leverage. 2. Remove the rotor. 3. Remove the bolts that attach the splash shield to the steering knuckle. Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Window Removal Procedure In order to remove the liftgate window weatherstrip from the pinch-weld flange, perform the following steps: 1. Open the liftgate window. 2. Firmly grip the weatherstrip. 3. Pull the weatherstrip. Installation Procedure 1. Open the liftgate window. 2. Push the weatherstrip onto the pinch-weld flange. Begin with the pre-formed corner at either upper corner of the liftgate window opening. 3. Completely seat the weather-strip around the liftgate window opening. Page 4091 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4971 Page 3961 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 6029 Page 6431 Air Door Actuator / Motor: Service and Repair Mode Actuator MODE ACTUATOR REPLACEMENT REMOVAL PROCEDURE The mode actuator is located on the top left side of the HVAC module. 1. Remove the knee bolster. 2. Remove the right side driver knee bolster bracket (2) from the steering column bracket (1) and the intermediate bracket (3). 3. Disconnect the vacuum connectors (1) from the mode actuator (5). 4. Remove the actuator rod retaining clip (4). 5. Remove the actuator rod (2) from the mode door lever (3). Page 2907 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. Page 9643 Abbreviations And Meanings - Part 24 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 7244 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 4804 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2721 Steps 7-10 Page 2489 Intake Air Temperature (IAT) Sensor Page 821 Registered And Non-Registered Trademarks - Part 3 Locations Relay Block - Body Relays, Except Envoy Locations Knock Sensor: Locations Mass Air Flow (MAF) Sensor And Intake Air Temperature (IAT) Sensor Page 2687 Abbreviations And Meanings - Part 7 Capacity Specifications Refrigerant System Capacities Park Brake Cable Replacement - Front Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake, if applied. 2. Remove the left trim panel-knee bolster. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Loosen the park brake cable at the equalizer. 5. Remove the front park brake cable from the connector. Page 8183 3. Remove the front side door lock pillar garnish molding from the vehicle. Feed the seat belt through the garnish molding. INSTALLATION PROCEDURE 1. Install the front side door lock pillar garnish molding to the vehicle. Feed the seat belt through the garnish molding. 2. Install the upper and the lower front seat belt anchor bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 70 N.m (52 lb ft). 3. Install the front and the rear door sill trim plates. Garnish Molding Replacement - Windshield Pillar GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE Page 9700 Arrows And Symbols Uses various symbols in order to describe different service operations Page 2642 Page 2336 1. Insert the CMP sensor through the reluctor wheel slot. 2. Install new CMP mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2.2 N.m (19 lb in). 3. Install the rotor onto the reluctor wheel. Page 3599 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EBCM to BPMV 39 inch lbs. EHCU to Bracket 7 ft. lbs. Page 6733 Blower Motor Relay Page 6746 A/C High Pressure Switch Page 819 Registered And Non-Registered Trademarks - Part 1 Page 5036 Abbreviations And Meanings - Part 25 Page 4719 6. Remove the brake drum. 7. Remove the rear brake shoes. 8. Disconnect the rear park brake cables from the chassis and rear axle housing retainers. Page 1872 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover wingnuts. 2. Remove the air cleaner cover. 3. Remove the air cleaner element. 4. Clear out any debris in the air cleaner housing. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner housing. 2. Install the air cleaner cover. Page 8107 6. Install the console compartment insert. 7. Install the console compartment insert screws. Tighten Tighten the nuts to 1.9 N.m (17 lb in). 8. Install the shift handle to the shift lever. 9. Install the shift handle retaining clip at the front of the handle. Page 1980 Fan Clutch: Specifications Fan Clutch Assembly Nut to Water Pump Pulley Stud ............................................................................................................................. 56 Nm (40 ft. lbs.) Fan Clutch Mounting Bolts .................................................................................................................. ..................................................... 33 Nm (24 ft. lbs.) Page 2189 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Page 8652 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 7579 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 535 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. Page 2562 Page 1610 Disclaimer Page 3971 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Page 786 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 5351 C317 (Body Harness To Driver's Seat Assembly Pigtail Connector) Page 7781 1. Install the center vent grille panel to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that secure the center vent grille panel to the cowl. Tighten the screws to 1.5 N.m (13 lb in). 3. Install the push-pin retainers securing the center vent grille panel to the cowl. 4. Install the right and the left vent grille end panels to the cowl. Tighten the screws to 1.5 N.m (13 lb in). 5. Install the screws securing the securing the right and the left vent grille ends to the cowl. 6. Install the windshield wiper arms. Page 5123 Abbreviations And Meanings - Part 16 Page 7227 Locations Electronic Components Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 293 2. Keeping the position lock pin on the new SOP switch, align the switch over the drive cables. IMPORTANT: The SOP switch comes from the factory with a position lock pin that is installed on top of the switch. This locks the timing gears in place. Do not remove the position lock pin until after the SOP switch and the actuator are installed. 3. Apply pressure to the SOP switch until the switch is completely seated. If the switch does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOP switch. Lift each cable into the switch, and press down on the assembly until the assembly is completely seated. 4. Install the screw which secures the SOP switch to the sunroof module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 3.4 N.m (30 lb in). 5. Connect the electrical connector to the SOP switch. 6. Install the sunroof motor/actuator. 7. Remove the position lock pin (1). 8. Remove the 2 alignment pins from the cable mechanisms and/or from the cam mechanisms. 9. Install the sunroof control module, but do not install the headliner until after the sunroof operation has been verified. 10. Verify the operation of the sunroof module. 11. Install the sunroof window. 12. Install the headliner. Page 9345 Page 8334 WA534F/54 - WA5456/43 Page 4674 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear Brake Hose Replacement - Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the vehicle with safety stands. 3. Clean the dirt and foreign material from the brake hose and brake pipe fitting. 4. Install a rubber cap or plug on the brake pipe fitting in order to prevent brake fluid loss and contamination. 5. Using a backup wrench, disconnect the brake hose and brake pipe fitting. 6. Remove the brake hose retainer. 7. Remove the brake pipe from the brake junction block. 8. Remove the brake junction block mounting bolt. 9. Remove the brake hose. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: After installation, ensure that the rear flex hose is not twisted and that the rear flex hose does not come in contact with any other components. 1. Install the brake junction block mounting bolt. Tighten the brake junction block bolt to 17 Nm (13 ft. lbs.). 2. Install the brake hose to the brake junction block. Tighten the brake hose fitting to 17 Nm (13 ft. lbs.). 3. Install the brake hose fitting to the brake pipe fitting. Tighten the brake hose fitting to 17 Nm (13 ft. lbs.). 4. Bleed the hydraulic brake system. 5. Remove the safety stands. 6. Lower the vehicle. Refer to Vehicle Lifting. Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Page 1218 Fuse Block - Underhood Connector C2 Part 1 Page 9398 Abbreviations And Meanings - Part 11 Page 579 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 8788 7. Disconnect the main feed electrical connector (1). 8. Remove the sunroof switch from the vehicle. INSTALLATION PROCEDURE 1. Position the ground wire (2) to the header. 2. Install the ground screw (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ground screw to 1.5 N.m (13 lb in). 3. Connect the main feed electrical connector (1). 4. Connect the electrical connector (3). 5. Operate the function of the sunroof switch (4). 6. Install the switch into the motor/actuator trim cover (5). Page 9549 Steps 18-21 Defogger Inoperative - Rear Window DEFOGGER INOPERATIVE - REAR WINDOW TEST DESCRIPTION Page 7768 Rear Bumper Reinforcement: Service and Repair Impact Bar Replacement - Rear Bumper (Utility) Removal Procedure 1. Remove the rear bumper step pads. 2. Remove the license plate lamps. 3. Remove the nuts and the bolts that retain the rear bumper impact bar to the bumper bracket. 4. Remove the rear bumper impact bar from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the rear bumper impact bar to the vehicle as follows: 1. Position the bumper impact bar on the bumper brackets so that the holes in the impact bar are aligned with the bracket holes. 2. Install 2 bolt plates and 4 nuts on top of the impact bar. 3. Install 2 bolt and nuts through the bottom of the impact bar. Tighten the rear bumper impact bar nuts to 90 N.m (66 lb ft). 2. Install the license plate lamps. 3. Install the rear bumper step pads. Page 2771 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module (BCM) C2 Part 1 Page 4932 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 2930 2. Install the TP sensor mounting screws. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The screws used to attach the TP sensor are coated with thread locking adhesive. Clean the attaching screw threads and apply thread locking material GM P/N 1052624 or equivalent. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the throttle body. 4. Connect the TP sensor harness connector. Page 935 9. Remove the CMP sensor. 10. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 11. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Drive out the roll pin with a suitable punch. 13. Remove the driven gear from the distributor shaft. Page 9411 Abbreviations And Meanings - Part 24 Page 7374 Page 2387 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the distributor. 3. Remove the fuel pipes. 4. Disconnect the knock sensor harness connector (3). 5. Remove the knock sensor retaining bolt (1). 6. Remove the knock sensor (2). INSTALLATION PROCEDURE 1. Install the knock sensor (2) and bolt (1). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the fuel pipes. Page 2671 Conversion English/Metric Part 1 Page 27 For vehicles repaired under warranty, use the table. Disclaimer Page 3713 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 5363 C500 (Body Harness To LF Door Harness) (W/ Power Locks/Windows) Part 1 Page 3993 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 2834 6. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent. 2. Install the ECT sensor in the engine. Tighten Tighten the sensor to 20 N.m (15 lb ft). Page 2686 Abbreviations And Meanings - Part 6 Page 6843 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Page 2694 Abbreviations And Meanings - Part 14 Page 8095 3. Use the J 38778 in order to release the rear carpet panel retainers. 4. Remove the rear inner panel carpet from the vehicle. Installation Procedure 1. Install the rear inner panel carpet to the vehicle. 2. Secure the rear inner panel carpet retainers to the body rear inner panel. 3. Install the jack storage cover. 4. Install the rear window garnish molding. Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the battery positive cable cover. 3. Remove the battery positive cable bolt. 4. Remove the battery positive cable from the underhood electrical center. 5. Remove the bolts that attach the underhood electrical center to the underhood electrical center support bracket. Page 5751 C224 (Body Harness To Ashtray Insert) Page 5459 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 697 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). Testing and Inspection Ignition Cable: Testing and Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Page 9948 1. Route the hose over the left wheelhouse panel. 2. Install the hose to the pump. 3. Install the hose to the nozzles. 4. Install the hose clip to the hood. 5. Close the hood. Page 9368 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 2526 Floor Pedals Page 9505 Abbreviations And Meanings - Part 1 Page 8267 Power Door Lock Actuator: Removal and Replacement Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws (2) that retain the lock actuator (1) to the latch. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. Installation Procedure 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Specifications Brake Drum: Specifications Rear Drum Brakes JM3 9.5 X 2 in. Discard Diameter 8.909 inch Maximum Allowable Diameter After Resurfacing 8.909 inch Maximum Allowable Radial Runout 0.006 inch Maximum Allowable Scoring 0.06 inch Original Drum Diameter 9.5 in. Maximum After Refinish 9.56 in. Replacement Discard 9.59 in. Maximum Out-of-Round or Taper 0.006 in. Page 5014 Abbreviations And Meanings - Part 3 Locations Neutral Safety Switch: Locations Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 8099 Console: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Park/Neutral Position-PNP Switch W/A/T 4.3L Shown, 2.2L Similar Park/Neutral Position (PNP) Switch (w/ A/T) (4.3L Shown, 2.2L Similar Page 8684 Abbreviations And Meanings - Part 4 Page 8251 Door Lock Cylinder Switch - Driver (w/o RKE) Page 3652 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 566 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 7776 2. Install the molding to the quarter panel rear window (4-Door only). 3. Install the molding fasteners to the quarter panel rear window (4-Door only). 4. Install the body side stationary window (2-Door only). Page 8643 Page 3318 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at top dead center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1) or V8 engine (2). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when the gear is installed in the distributor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. Page 3924 9. Push the range selector cable grommet up through the floor panel of the vehicle. 10. Lower the vehicle. 11. Remove the console. 12. Remove the front mat and carpet. 13. Ensure that the transmission is in the mechanical neutral position. 14. Disconnect the cable end from the controller ball stud. 15. Remove the retainer securing the cable to the controller. 16. Depress the tangs and remove the cable from the controller. 17. Remove the sound deadening material from the floor panel that covers the cable. 18. Pull the cable up through the opening in the floor_ panel and remove the cable from the vehicle. Installation Procedure Page 9124 Abbreviations And Meanings - Part 2 Page 7282 Abbreviations And Meanings - Part 8 Page 1207 Fuse Block - I/P Part 3 Page 2246 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 832 2. Install the power window switch to the trim panel by pressing down. Ensure that the retainers lock into place. Page 2200 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct. 3. Move the air intake assembly aside. 4. Drain the cooling system below the level of the engine coolant temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 5. Disconnect the ECT sensor harness connector. Page 9062 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. 3. Install the CPA to the I/P module yellow 2-way connector (1) located behind the I/P support. Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Weatherstrip Replacement - Rear Door Window Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Open the rear side door window. 2. Remove the rear side door window weatherstrip. Start the at butt joint and pull the weatherstrip from the window opening. Installation Procedure 1. Install the rear side door weatherstrip. 2. Locate the butt joint at the bottom center of the window opening and set the weatherstrip around the window opening. Page 5129 Abbreviations And Meanings - Part 22 Page 2928 Throttle Position (TP) Sensor Page 3026 Steps 15-17 Page 823 Registered And Non-Registered Trademarks - Part 5 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 2631 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Service and Repair Wiper Control Module: Service and Repair WIPER MOTOR MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cover and three screws. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Page 8476 20. Install the coat hooks and retaining screws. Tighten Tighten the retaining screws to 1.4 N.m (12 lb in). 21. Install the assist handle, the bolts and covers. Tighten Tighten the screws that retain the handle to 9 N.m (80 lb in). 22. Install the upper rear seat belt anchor bolts and covers. When installing the rear seat belt anchors, take care not to pinch the drain hose with the anchor bracket. The hose should sit flat on the back of the headliner. Tighten Tighten the anchor to 80 N.m (59 lb in). 23. Install the upper front seat belt anchor bolts and covers. Tighten Tighten anchor bolts to 70 N.m (52 lb in). 24. Return the rear seats to the upright position. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3753 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 2459 10. Remove the mounting clamp hold down bolt. 11. Remove the distributor. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than 1 clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving proper rotor alignment during the distributor installation. INSTALLATION PROCEDURE 1 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the 2 marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. INSTALLATION PROCEDURE Page 2502 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module (BCM) C3 Part 1 Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 1 Page 4651 5. Remove the piston seal from the caliper bore. Do not use a metal tool. 6. Remove the bleeder valve and bleeder valve cap from the caliper body. 7. Remove the guide pins and guide pin sleeves from the anchor bracket. 8. Clean the following components with denatured alcohol. ^ The bleeder valve ^ The caliper bore ^ The caliper passages ^ The piston ^ The lining contact area on the anchor bracket. 9. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 10. Replace the piston or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore. Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Notice: Refer to Fastener Notice in Service Precautions. 11. Replace the bleeder valve cap. Tighten the bleeder valve to 12 Nm (110 inch lbs.). Assembly Procedure Page 4570 3. Install the brake caliper mount. 4. Install the brake pads. 5. Install the brake caliper. 6. Burnish replaced or refinished rotors. Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Notice: Refer to Brake Caliper Notice in Service Precautions. Page 5890 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 5705 C413 (Engate Harness To Body Harness) Page 2665 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 6725 A/C Accumulator Page 1694 Oil Filter Adapter: Service and Repair Remote Oil Filter Adapter Replacement Remote Oil Filter Adapter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the engine oil filter. 4. Remove the engine oil cooler pipes from the remote engine oil filter adapter. 5. Remove the remote oil filter inlet and outlet hoses from the remote oil filter adapter. 6. Remove the nuts and the remote oil filter adapter from the remote oil filter mounting bracket. 7. If necessary, remove the remote oil filter adapter mounting bracket and bolts from the radiator support. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the remote oil filter adapter mounting bracket and bolts to the radiator support, if removed. Tighten the remote oil filter adapter mounting bracket bolts to 30 Nm (22 ft. lbs.). 2. Install the remote oil filter adapter and nuts to the mounting bracket. Tighten the remote oil filter adapter nuts to 25 Nm (18 ft. lbs.). 3. Install the remote oil filter inlet and outlet hoses to the remote oil filter adapter. 4. Install the engine oil cooler pipes to the remote engine oil filter adapter. 5. Install the engine oil filter. 6. Lower the vehicle. 7. Operate the engine and check for leaks. 8. Inspect the engine oil level and fill to the proper level. Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Page 3309 9. Remove the CMP sensor. 10. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. 11. Support the distributor drive gear in a V-block or similar fixture. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Drive out the roll pin with a suitable punch. 13. Remove the driven gear from the distributor shaft. Page 3872 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 1210 Fuse Block - Underhood Connector C1 Part 1 Page 2256 Intake Air Temperature Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the intake air temperature (IAT) sensor harness connector. Intake Air Temperature (IAT) Sensor 3. Remove the IAT sensor by pulling straight out using a rotating motion. INSTALLATION PROCEDURE Page 9633 Abbreviations And Meanings - Part 14 Page 5031 Abbreviations And Meanings - Part 20 Page 2098 4. Remove the air cleaner outlet duct from the throttle body. 5. Remove the intermediate steering shaft. 6. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 7. Remove the radiator inlet hose support bracket and nut. 8. Raise the vehicle. Refer to Vehicle Lifting. 9. Disconnect the exhaust pipe from the exhaust manifold. 10. Lower vehicle, 11. Remove the front tire to gain access to the rear exhaust manifold bolts. Page 7317 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING - UNIVERSAL GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(tm) at 1-800-355-3515 in order to address this problem. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLink(tm) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(tm) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Page 1840 1. Install the NEW engine front cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine front cover bolts. Tighten the bolts to 12 Nm (106 inch lbs.). Important: DO NOT reuse the original crankshaft position sensor seal (O-ring). When installing the crankshaft position sensor be sure the crankshaft position sensor is fully seated and held stationary in the engine front cover crankshaft position sensor bore. A crankshaft position sensor that is not completely seated will cock in the engine front cover and may result in erratic engine operation. 3. Lubricate the NEW crankshaft position sensor seal (O-ring) with clean engine oil. 4. Install the NEW crankshaft position sensor seal (O-ring) onto the crankshaft position sensor. 5. Install the CKP sensor. 6. Install the water pump. 7. Install the crankshaft balancer. 8. Install the engine oil pan. Page 5339 C300 (Dome Lamp Harness To Sunroof Harness) Page 6794 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 and SIR Disabling and Enabling Zone 3. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the floor console, if equipped. 3. Cut an "X" in the carpet over the inflatable restraint sensing and diagnostic module (SDM). 4. Fold the carpet back to expose the SDM. 5. Remove the connector position assurance (CPA) (4) from the SDM harness connector (3). 6. Disconnect the SDM harness connector (3) from the SDM (2). 7. Remove the SDM mounting fasteners (1). 8. Remove the SDM (2) from the vehicle. 9. Repair the fasteners using the following procedure: IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 9.1. Remove the stripped nut and discard the nut. 9.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 9.3. Condition the floor panel attaching surface where the new stud is to be installed. 9.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 9.5. Migweld the stud at the drilled holes from above or below the floor pan (as required). 9.6. Apply body sealer GM P/N 9984248 around any exposed openings. 9.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Page 5235 C106 (Forward Lamp Harness To Body Harness) Part 2 C106 (Forward Lamp Harness To Body Harness) (Export) Page 1341 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Body Relay Block Page 3420 4. Install the distributor. 5. Connect the negative battery cable. Page 3095 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool SYSTEM DESCRIPTION The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-3 Page 3957 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 5329 C211 (Steering Column Harness To Body Harness) Part 1 Page 3968 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 4366 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 3313 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. Page 7866 4. Slide the lower latch cover down the latch rod until it is retained on the latch bolt threads. 5. Install the door trim panel. Page 5502 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 6045 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Specifications Brake Fluid: Specifications Fluid Type See Note use only Delco Supreme or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 2580 Instrument Panel, LF Page 9381 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 3623 4. Install the J25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Notice: Refer to Fastener Notice in Service Precautions Page 7495 Speaker: Service and Repair Speaker Replacement - Rear Door SPEAKER REPLACEMENT - REAR DOOR TOOLS REQUIRED J 34940 Rivet Gun REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the radio rear side door speaker retaining rivets. 3. Remove the radio rear side door speaker. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the radio side rear door speaker. 3. Install the speaker retaining rivets using J 34940. 4. Install the door trim panel. 5. Inspect for proper circuit operation. Page 9609 Arrows And Symbols Uses various symbols in order to describe different service operations Page 7271 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 8598 Tighten the seat back bolts to 24 N.m (18 lb ft). 3. Connect the electrical connector for the seat back recliner motor, if equipped. 4. Install the seat cushion trim cover and pad. 5. Install the seat back cover and pad. 6. Install the seat in the vehicle. Page 7599 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 6308 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 742 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Specifications Oil Pressure Sender: Specifications Engine Oil Pressure Gage Sensor ............................................................................................................................................................. 30 Nm (22 ft. lbs.) Engine Oil Pressure Gage Sensor Fitting - Plus Required Angle ............................................................................................................. 15 Nm (11 ft. lbs.) Page 8451 Sunroof Opening Position Switch Page 1303 2. Install the spare tire carrier to body side inner panel mounting bolts. Tighten Tighten the spare tire carrier to body side inner panel mounting bolts to 30 Nm (22 ft. lbs.). 3. Install the spare tire to the spare tire carrier. 4. Install the spare tire to the spare tire carrier mounting nut. 5. Install the spare tire cover. Page 4212 Seals and Gaskets: Service and Repair NV 3500 Transmission Housing Oil Seal Replacement - Front Transmission Housing Oil Seal Replacement - Front ^ Tools Required J 38801 Input Seal Installer Removal Procedure 1. Remove the transmission. 2. Remove the 2 clutch actuator bolts. 3. Remove the clutch actuator from the input shaft. 4. Remove the 6 bolts from the front bearing retainer. Carefully remove the front bearing retainer. Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 7682 Abbreviations And Meanings - Part 10 A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 7308 Garage Door Opener Transmitter: Electrical Diagrams Garage Door Opener Diagram Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement Removal Procedure 1. Remove the lower bumper valance. 2. Remove the bolts from the tow hooks. 3. Remove the hooks from the frame. Installation Procedure 1. Install the tow hooks to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the tow hooks. Tighten the bolts to 55 N.m (41 lb ft). 3. Install the lower bumper valance. Page 2809 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 8583 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. Installation Procedure 1. Install the switch assembly to the trim panel by snapping the switch into the plastic retaining clips. Page 7285 Abbreviations And Meanings - Part 11 Page 3082 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 2734 Engine Harness Rear (4.3L) Page 909 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. Page 499 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP system variation learn procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Page 9583 Page 7631 Page 9162 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION The driver information center (DIC) consists of a multi-function electronic display placed in the overhead console. The DIC displays the following information: - The vehicle fuel information - The outside temperature - The direction the vehicle is facing The display parameters are cycled, changed, and acknowledged using the following 2 DIC buttons mounted at the side of the driver information center: US/MET: Allows the display to switch between English and Metric units. MODE: Used to toggle between OFF, COMP/TEMP and TRIP. COMP/TEMP COMP: In the Compass Mode, one of eight compass readings (N, NE, E, SE, S, SW, W, and NW) will be displayed to indicate the direction the vehicle is facing. TEMP: In the Temperature Mode, the outside air temperature is displayed in either °C or °F. If the outside air temperature is below 3°C (37°F), the display will toggle between ICE and the current outside air temperature in 8 second increments. TRIP: In the Trip Mode, the DIC displays the following information based on class 2 serial data: AVG ECON: The DIC displays the average fuel economy since the last reset. AVG SPEED: The DIC displays the average speed since the last reset. FUEL USED: The DIC displays the amount of fuel used since the last reset. INST ECON: The DIC displays the instantaneous fuel economy since the last second of driving. RANGE: The DIC displays the estimated distance that can be travelled with the remaining fuel in the tank, based on the fuel economy for the last few hours of driving. The display format for each mode is indicated in the table. Page 4509 7. Install the boot seals into the caliper housing bores using the J8092 and the J43885. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear Disassembly Procedure 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 3. Remove the piston from the caliper bore. 4. Remove the boot from the caliper bore. Do not scratch the housing bore. Page 8981 Conversion English/Metric Part 3 Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Special Tools Ordering Information SPECIAL TOOLS ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 am-7:00 pm Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 am-6:00 pm EST Fasteners FASTENERS Page 7647 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8631 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Removal Compressor Clutch Hub: Service and Repair Removal V7 - Direct Mount COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V7 - DIRECT MOUNT) TOOLS REQUIRED - J 33013-B Hub and Drive Plate Remover/Installer - J 33027-A Clutch Hub Holding Tool - J 41790 A/C Compressor Holding Fixture 1. Remove the A/C compressor from the vehicle. 2. Clamp the A/C compressor holding fixture, J 41790 in a vise and attach the A/C compressor to the J 41790. 3. Hold the clutch hub and drive plate assembly (2) in place using the J 33027-A. 4. Remove the A/C compressor shaft nut with a 13 mm socket (1). Page 5254 C203 (Body Harness To IP Harness) Part 9 Page 8059 3. Raise the frame slightly on the hoist. 4. Install the lower cushion. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the frame cushion bolts. Tighten the bolts to 70 N.m (52 lb ft). 6. Lower the hoist. Page 1547 8. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine. 9. Install the crankshaft balancer washer and the bolt. Tighten the crankshaft balancer bolt to 95 Nm (70 ft. lbs.). 10. Install the drive belt. 11. Install the fan shroud assembly. 12. Connect the negative battery cable. Page 4272 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 3935 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 8201 2. Install the upper and the lower front seat belt anchor bolts. Tighten the screws to 70 N.m (52 lb ft). 3. Install the front and the rear door sill trim plates. Garnish Molding Replacement - Sunroof Panel Window (ZRX/EXTREME w/ CF5) Garnish Molding Replacement - Sunroof Panel Window (ZRX/EXTREME w/ CF5) Removal Procedure 1. With a medium flat-bladed tool, remove the service cover. 2. Remove the motor/actuator trim cover screw (2). 3. Lower the motor/actuator trim cover and remove the sunroof switch (4) from the cover (5). Page 342 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Page 2612 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. With Air Conditioning With A/C Page 6186 Shackle: Service and Repair Spring Shackle Replacement Spring Shackle Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank (2-door utilities only). 3. Remove the EVAP canister (2-door utilities only), if necessary. 4. Remove the spare tire, if necessary. 5. Disconnect rear exhaust hangers and lower exhaust system, if necessary. 6. Support the rear axle. 7. Remove the frame to spring shackle mounting nut and bolt. 8. Remove the leaf spring to spring shackle mounting nut and bolt. 9. Remove the spring shackle from the vehicle. Installation Procedure 1. Install the spring shackle to the vehicle. 2. Install the spring shackle to leaf spring mounting bolt and nut. Do not tighten the nut. 3. Install the frame to the spring shackle mounting bolt and nut. Do not tighten the nut. Page 8593 1. Remove the seat from the vehicle. 2. Remove the seat back recliner handle. 3. Remove the 4 J-strips (1) securing the seat cover to the frame. 4. Remove spring (2) from the seat adjuster. 5. Pull the seat cushion pad and cover back to expose the frame. 6. Remove the 2 nuts (1) securing the seat adjuster rail to the frame. 7. Remove the cable (2) from the clip (1) on the adjuster rail. 8. Remove the cable (2) from the hole in the adjuster rail. 9. Remove the cable from the pass through hole (2) in the adjuster rail. Locations Ignition Coil, Ignition Control Module (ICM), Manifold Absolute Pressure (MAP) Sensor, Throttle Body, And EVAP Canister Purge Solenoid Page 4592 Brake Drum: Service and Repair Brake Drum Refinishing Brake Drum Refinishing Tools Required ^ J42450-A Wheel Hub Resurfacing Kit Important: DO NOT refinish the brake drums in order to correct any of the following complaints: ^ A growl or squeal brake noise ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the drum braking surface ^ Drum discoloration Refinish the brake drums ONLY when one or more of the following conditions exist: ^ Severe scoring where the groove depth exceeds the specification for the braking surface. ^ Brake pulsation caused by the following: Brake drum runout in excess of specification - Corrosion or pitting that is deeper than the drum braking surface 1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the brake drum exceeds the brake drum maximum refinish diameter, DO NOT refinish the brake drum. Replace the brake drum. 2. Use the J42450-A in order to THOROUGHLY clean the rust from the brake drum flange. 3. Refinish the brake drum. Refer to the brake lathe manufacturers operating instructions. 4. Using denatured alcohol, clean the braking surfaces. 5. Using non-lubricated, filter compressed, dry the braking surfaces. Page 748 Page 4637 Brake Caliper: Service and Repair Brake Caliper Replacement - Front (Single Piston) Brake Caliper Replacement - Front (Single Piston) Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, using an appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 7502 Tape Player: Service and Repair Cassette Player Care and Cleaning CASSETTE PLAYER CARE AND CLEANING TOOLS REQUIRED J 39916-A CD and Cassette Diagnostic Audio Kit Follow the recommended cleaning schedule: - Clean the cassette player every 15 hours for the best performance. - Clean the cassette player every 50 hours in order to prevent damage to the tape head. Clean the following 2 parts on the tape player: - The head - The capstan Leave the tape player in the vehicle, since you can reach the parts through the tape door. Perform this service at least every 50 hours of cassette operation. After 50 hours of tape play, CLN (Clean) appears on the display as a reminder. Although the system will still function when this message is displayed, the following conditions may occur until the head and the capstan are cleaned: - Reduced sound quality - Damage to the cassette tapes After cleaning the cassette tape player, press and hold EJECT for 5 seconds in order to reset the CLN indicator. The radio displays - - - in order to show that the clean feature has been reset. Failure to clean the cassette player regularly may cause the following conditions: - Reduced sound quality - Damage to the cassettes - Damage to the mechanism Keep the cassette tapes correctly stored in their plastic cases away from the following conditions: - Contaminants - Direct sunlight - Extreme heat Failure to correctly store the cassette tapes may cause the following conditions: - Improper operation of the cassette tapes - Premature failure of the tape player The cassettes are subject to wear. The sound quality may degrade over time. Before servicing a tape player, verify that the following conditions exist: - The cassette tape is in good condition. - The tape player is clean. Clean the tape player at least after every 50 hours of use in order to provide optimum performance. The radio displays CLN as a reminder every 50 hours. If a reduction in the sound quality occurs, regardless of when the tape player was last cleaned, play a different cassette tape in order to see if the tape or the tape player is at fault. If the second cassette tape results in no improvement in sound quality, clean the tape player. Page 8975 Equivalent - Decimal And Metric Part 1 Page 1503 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve rocker arm assemblies as follows: 4.1. Finger start the bolt at location (1). 4.2. Finger start the bolt at location (2). 4.3. Finger start the bolt at location (3). 4.4. Finger start the remaining valve rocker arm bolts. 5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57 - 63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the valve rocker arm bolts Tighten valve rocker arm bolts to 30 Nm (22 ft. lbs.). 7. Install the valve rocker arm cover. Page 9740 Registered And Non-Registered Trademarks - Part 3 Page 9200 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Connect the inflatable restraint front end discriminating sensor connectors to the inflatable restraints front end discriminating sensor. 2. Install the CPA to the inflatable restraints front end discriminating sensor connectors. 3. Install the SIR fuse into the I/P fuse block (1) located in the I/P fuse block. 4. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 4.1. The AIR BAG indicator will flash 7 times. 4.2. The AIR BAG indicator will then turn OFF. 5. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the 3 screws securing the trim panel to the seat. 3. Disconnect the electrical connector from the switch. 4. Remove the switch from the trim panel by snapping the switch out of the plastic retaining tabs. 5. Remove the switch assembly. INSTALLATION PROCEDURE Page 7261 Equivalent - Decimal And Metric Part 1 Locations Sunroof Components (ZRX, Extreme W/ CF5) Page 4996 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Service and Repair Amplifier: Service and Repair AMPLIFIER REPLACEMENT REMOVAL PROCEDURE 1. Remove the negative battery cable. CAUTION: Refer to Battery Disconnect Caution Battery Disconnect Caution in Service Precautions. 2. Remove the floor console from the vehicle. 3. Remove remote CD changer, if equipped. 4. Remove the console wiring harness from the amplifier. 5. Remove the amplifier mounting nuts. 6. Remove the amplifier from the mounting bracket. INSTALLATION PROCEDURE 1. Install the amplifier to the mounting bracket. 2. Install the amplifier mounting nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the amplifier mounting bracket bolts to 10 N.m (88 lb in). 3. Install the console wiring harness to the amplifier. 4. Install the remote CD changer, if equipped. 5. Install the floor console to the vehicle. Removal Compressor Clutch Bearing: Service and Repair Removal With RPO Code HT6/HD6/HU6 CLUTCH ROTOR AND/OR BEARING REMOVAL (With RPO Code HT6/HD6/HU6) TOOLS REQUIRED - J 6083 External Snap Ring Pliers - J 33023-A Puller Pilot - J 41552 Compressor Pulley Puller - J 29886 Driver Handle - J 9398-A Bearing Remover 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: - The pulley rotor (1) - The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6077 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 9122 CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT: The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800- 393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Page 595 4. Remove the distributor cap. 5. Remove the rotor screws. 6. Remove the rotor. Page 3027 Steps 18-23 Page 4211 4. Install the input shaft bearing retainer to the clutch housing. 5. Install the 5 bearing retainer bolts. Tighten Tighten the 5 bearing retainer bolts to 29 Nm (21 ft. lbs.). 6. Install the clutch actuator to the input shaft. 7. Install the clutch actuator bolts. ^ Tighten the clutch actuator bolts to 8 Nm(71 inch lbs.). 8. Install the transmission. 9. Install the rear propeller. 10. Fill the transmission to the proper fluid level. 11. Lower the vehicle. 12. Bleed the clutch system. Page 9675 Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 761 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 2899 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 8236 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 6854 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESSES The inflatable restraint wiring harnesses connect the sensing and diagnostic module (SDM), inflator modules, discriminating sensors, and the class 2 serial data circuit together using weather pack connectors. SIR system connectors are yellow in color for easy identification. When repairing SIR system wiring harnesses, follow the proper testing and wiring repair procedures. Locations Power Seat Switch: Locations Seat Switches Page 8566 Seat Adjuster Switch - Driver (w/ 6-Way) Part 2 Page 7629 Page 1764 7. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. 8. Disconnect the vacuum hose from the intake manifold for the vacuum tank. 9. Remove the power brake booster vacuum hose. 10. Disconnect the following electrical connectors: ^ The A/C compressor clutch (1) ^ The A/C compressor cutoff switch (5), if equipped ^ The Throttle Position (TP) sensor (2) ^ The Idle Air Control (IAC) motor (3) 11. Disconnect the following electrical connectors: ^ The fuel meter body assembly (1) ^ The Manifold Absolute Pressure (MAP) sensor (3) ^ The EVAP canister purge solenoid valve (2) 12. Remove the engine wire harness clip from the accelerator cable bracket. 13. Move the engine wiring harness aside. Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Page 5789 Splice Pack SP101 Page 1655 Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Without Air Conditioning Drive Belt Idler Pulley Replacement - without Air Conditioning Removal Procedure 1. Remove the drive belt. 2. Remove the belt idler pulley bolt. 3. Remove the belt idler pulley from the power steering pump mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the belt idler pulley and the bolt to the power steering pump mounting bracket. Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Page 5140 Auxiliary Power Outlet: Connector Views Accessory Power Outlet - Left Page 4728 Parking Brake Cable: Service and Repair Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure Tools Required ^ J37043 Park Brake Cable Release Tool 1. Release the park brake, if applied. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the right rear park brake cable from the equalizer. 4. Remove the spring from the equalizer, if equipped. 5. Remove the park brake from the connector. Page 5757 C302 (Power Seat Harness, LH To Power Recliner Harness, LH) (w/ Power Seats, Memory) Page 5166 Fuse Block - I/P Part 2 Page 5284 C317 (Body Harness To Driver's Seat Assembly Pigtail Connector) Page 7256 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7909 Tighten the bolt to 25 N.m (18 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Impact Bar Replacement - Front Bumper Front Bumper Reinforcement: Service and Repair Impact Bar Replacement - Front Bumper Impact Bar Replacement - Front Bumper Removal Procedure 1. Remove the grille. 2. Remove the radiator air intake baffle. 3. Remove the front wheel opening flare extension, if equipped. 4. Remove the nut and the bolt that retain the brace to the bumper impact bar. 5. Disconnect the fog lamp connectors. 6. Remove the nuts and the bolts that retain the bumper impact bar to the frame. 7. Remove the bumper impact bar from the vehicle. 8. If replacing the bumper impact bar, perform the following: 1. Remove the license plate bracket, if equipped. 2. Remove the air deflector from the bumper impact bar. Installation Procedure 1. Install the following components if removed: 1. Install the air deflector to the bumper impact bar. 2. Install the license plate bracket. 2. Install the bumper impact bar to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts that retain the bumper impact bar to the frame. Tighten the bumper impact bar to the frame bolts to 40 N.m (30 lb ft). 4. Install the fog lamp connectors. 5. Install the nuts and the bolts that retain the bumper impact bars to the brace. Tighten the bumper impact bar to the brace bolts to 40 N.m (30 lb ft). Page 3498 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the electrical connector from the sensor. 4. Remove the bolt (2). 5. Using a twisting and pulling motion, remove the vehicle speed sensor (1) from the case. 6. Remove and discard the O-ring seal (3). Installation Procedure 1. Install the new O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with clean transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Remove the drain pan. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON (R) III transmission fluid. Page 336 For vehicles repaired under warranty, use the table. Disclaimer Page 2137 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. 1. Remove the left instrument panel sound insulator from the vehicle. 2. Remove the lower instrument panel sound insulator from the vehicle. 3. Disconnect the electrical connectors from the body control module. 4. Bend the 2 snap retainers back slightly and pull the body control module from the bracket at an angle. INSTALLATION PROCEDURE 1. Install the body control module to the bracket at an angle under the wide hook retainer, with the label facing away from the bracket. 2. Apply pressure on the left side of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 3. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. 4. Connect the electrical connectors to the body control module. Be sure to connect the brown connector last. 5. Install the lower instrument panel sound insulator to the vehicle. 6. Install the left instrument panel sound insulator to the vehicle. 7. Use the following components in order to program the body control module with the proper calibrations: - The Techline Terminal - The scan tool 8. Perform the BCM Programming. See: Testing and Inspection/Programming and Relearning 9. Clear the diagnostic trouble codes (DTCs). Page 2798 The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. See: Testing and Inspection/Diagnostic Trouble Code Descriptions DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. NOT RUN SCC (NOT RUN SINCE CODE CLEAR): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 4861 Page 9712 Abbreviations And Meanings - Part 2 Page 2613 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (2-Door Utility). 4. Remove the fuel tank. 5. Disconnect the fuel tank pressure sensor electrical connector. 6. Remove the fuel tank pressure sensor (1) from fuel sender assembly (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) on the fuel sender assembly (2). 2. Connect the fuel tank pressure sensor electrical connector. 3. Install the fuel tank. 4. Refill the fuel tank. 5. Install the fuel filler cap. 6. Connect the negative battery cable. 7. Inspect for leaks. 7.1. Turn ON the ignition for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition. 7.4. Inspect for fuel leaks. Page 6609 Control Assembly: Service and Repair HVAC CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel accessory trim plate. 2. Remove the HVAC control assembly retaining screws. 3. Depress the HVAC control assembly retaining tabs and remove the HVAC control assembly from the instrument panel. 4. Disconnect the vacuum harness connector from the HVAC control assembly. 5. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control assembly. 2. Connect the vacuum harness connector to the HVAC control assembly. Page 8374 WA534F/54 - WA5456/43 Page 9743 Power Window Switch: Connector Views Door Lock And Window Switch - Driver C1 Part 1 Page 802 Abbreviations And Meanings - Part 11 Page 3083 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn the ignition OFF. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Engine Controls - Revised DTC P0336 Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0336 Bulletin No.: 03-06-04-033A Date: February 26, 2004 SERVICE MANUAL UPDATE Subject: Revised DTC P0336 Models: 2004 Buick Rainier 2003 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Astro, Blazer, Express, Kodiak, S-10, TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Silverado HD, Suburban, Tahoe 2003 GMC Sierra, Sierra HD, Sierra Denali, TopKick, Yukon, Yukon Denali, Yukon XL 2003-2004 GMC Envoy, Envoy XL, Jimmy, Safari, Savana, Sonoma 2004 GMC Envoy XUV 2003-2004 HUMMER H2 2003-2004 Isuzu Ascender, NPR/NQR Commercial Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, P, T, Z, U, N, G - RPOs LU3, LR4, LM4, LM7, L59, LQ4, LQ9, L18) Supercede: This bulletin is being revised to correct the information. Please discard Corporate Bulletin Number 03-06-04-033 (Section 06 - Engine/Propulsion System). Page 5083 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 5331 C211 (Steering Column Harness To Body Harness) Part 3 Page 9562 * The defogger terminal Important: Do not remove the holding force until the solder has solidified. 14. Remove the excess flux with the solvent. 15. Connect the electrical connector. Page 7089 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 8349 WA8555/41 - WA8555/41 Page 9835 Abbreviations And Meanings - Part 21 Page 9798 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 7087 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 7278 Abbreviations And Meanings - Part 4 Page 78 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 3828 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the~ transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 4558 4. Install the brake caliper and mounting bracket, 4 wheel drive vehicles. 5. Install the brake caliper, 2 wheel drive vehicles. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Refer to Vehicle Lifting. Specifications Compression Check: Specifications Compression Pressure Limit ............................................................................................................... ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest. Page 9728 Abbreviations And Meanings - Part 18 Page 6192 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 4043 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 9021 Audible Warning Device: Electrical Diagrams Audible Warnings Diagram 1 Page 9108 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 9063 4. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 5. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 6. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 7. Install the knee bolster. 8. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 8350 WA8555/41 - WA8624/50 Page 9001 Abbreviations And Meanings - Part 13 Page 5694 C306 (Body Harness To RR Door Harness) (4-Door) Page 6058 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Page 5554 Auxiliary Power Outlet: Connector Views Accessory Power Outlet - Left Page 9019 Registered And Non-Registered Trademarks - Part 4 Page 9217 Odometer: Description and Operation ODOMETER The IPC contains a season odometer and a trip odometer. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC displays the vehicle mileage and trip mileage as determined by the IPC. The IPC calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. Specifications Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 1076 1. Install the radiator inlet hose to the coolant outlet. 2. Using the J 38185, reposition the radiator inlet hose clamp to the coolant outlet. 3. Install the radiator inlet hose to the radiator. 4. Using the J 38185, reposition the radiator inlet hose clamp to the radiator. 5. Install the radiator inlet hose to the radiator support. 6. Install the air cleaner outlet duct. 7. Fill the cooling system. 8. Inspect the cooling system for leaks. Page 3288 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the vehicle. 9. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 5693 C305 (Body Harness To LR Door Harness) (4-Door) Page 8656 Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - FUSES A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 2130 Body Control Module (BCM) C2 Part 2 Page 9692 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2385 Knock Sensor (KS) Page 7684 Abbreviations And Meanings - Part 12 Page 6407 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: ^ The wheel/nut has the word Metric stamped on the face. ^ The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters gap per thread Page 2176 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 8080 Ash Tray: Removal and Replacement Ashtray Replacement Removal Procedure 1. Remove the instrument panel trimplate. 2. Remove ashtray housing retaining screws. 3. Move the ashtray housing rearward in order to disconnect the electrical connectors. 4. Remove the clip that retains the electrical connectors to the instrument panel. 5. Disconnect the electrical connectors. 6. Remove the ashtray housing from the instrument panel. Installation Procedure 1. Install the ashtray housing to the instrument panel. 2. Position the ashtray housing in order to connect the electrical connectors. 3. Connect the electrical connectors. 4. Install the electrical connector retaining clip to the instrument panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the screws that retain the ash tray housing to the instrument panel. Tighten the screws to 1.9 N.m (17 lb in). 6. Install the instrument panel trimplate. Page 2868 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Page 4258 2. Install the following parts: 2.1. The O-ring on the vehicle speed sensor assembly. 2.2. The vehicle speed sensor assembly. 2.3. Tighten Tighten the bolt to 16 Nm (12 ft. lbs.). 3. Install the electrical connector to the vehicle speed sensor. 4. Lower the vehicle. Page 8505 5. Install the interior window panel garnish molding (1). 6. Clean the sunroof window. A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 7935 Disclaimer Page 8746 Seat Harness Routing (8-Way w/o Memory) Page 4000 Page 9481 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Handle Replacement - End Gate (Utility) Tailgate Release Handle: Service and Repair Handle Replacement - End Gate (Utility) Handle Replacement - End Gate (Utility) Removal Procedure 1. Remove the handle grip screws. 2. Remove the liftgate trim panel. 3. Release the liftgate handle rod retainer. 4. Remove the bolts that retain the liftgate outside handle to the liftgate. 5. Remove the liftgate outside handle from the liftgate. Installation Procedure Page 2157 Engine Control Module: Description and Operation Vehicle/Powertrain Control Module & the BCM VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(tm) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 1625 Drive Belt Rumbling Diagnosis Step 1 - 8 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Capacity Specifications Refrigerant System Capacities Page 5062 Page 3878 Shifter A/T: Service and Repair Floor Shift Control Boot Replacement Removal Procedure 1. Remove the retainer securing the shift boot to the console trim. 2. Remove the shift boot from the console trim by lightly prying on the boot tabs. Installation Procedure 1. Install the shift boot to the console trim. 2. Install the retainer securing the shift boot to the console trim. Page 8377 WA722J/25 - WA765J/37 Locations Electronic Components Page 8641 Page 5589 Fuse Block - Underhood Connector C1 Part 6 Page 3385 Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 5522 Abbreviations And Meanings - Part 1 Locations Camshaft Position (CMP) Sensor, Knock Sensor (KS), And Engine Oil Pressure (EOP) Switch Page 9201 2. Connect the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 3. Install the CPA to the steering wheel module yellow 2-way connector (1) located near the knee bolster. 4. Install the SIR fuse to the I/P fuse block (1) located in the I/P fuse block. 5. Install the knee bolster. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the I/P module yellow 2-way connector (1) located behind the main I/P support. Page 5875 For vehicles repaired under warranty, use the table. Disclaimer Page 6006 3. Remove the key from the ignition. 4. Remove the knee bolster. 5. Remove the SIR fuse from the I/P fuse block (1) located in the I/P fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 2-way connector (1) located near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 1527 Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Removal Procedure Important: Do not remove the crankshaft rear oil seal housing if only replacing the crankshaft rear oil seal. 1. Remove the oil pan. 2. Remove the engine flywheel. 3. Remove the bolts and the nut holding the crankshaft rear oil seal housing to the engine. 4. Remove the crankshaft rear oil seal housing. 5. Remove and discard the crankshaft rear oil seal housing gasket. 6. Clean all the sealing surfaces. 7. Inspect and replace the crankshaft rear oil seal housing for warping, cracks. wear, or damage. Installation Procedure Important: When installing a NEW crankshaft rear oil seal housing the crankshaft rear oil seal will come with the housing. If reusing the housing and then installing a NEW seal follow the instructions for installing the housing and than refer to Crankshaft Rear Oil Seal Replacement. Page 9511 Abbreviations And Meanings - Part 7 Page 7415 Disclaimer Page 7692 Abbreviations And Meanings - Part 20 Page 9666 Page 5342 C301 (Dome Harness To Overhead Console) (w/o GDO) Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Level Indicator Tube Bolt ............................................................................................................................................................. 12 Nm (106 inch lbs.) Page 718 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 9578 Page 7170 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 7439 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 2608 7. Install the fuel tank. 8. Refill the fuel tank. 9. Install the fuel filler cap. 10. Connect the negative battery cable. 11. Inspect for leaks. 11.1. Turn ON the ignition for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition. 11.4. Inspect for fuel leaks. Page 8207 4. Install the coat hook plug (1) into the trim panel (2). Body Relay Block Sunroof Motor/Actuator Replacement RPO Code Zrx/Extreme W/CF5 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement RPO Code Zrx/Extreme W/CF5 SUNROOF MOTOR/ACTUATOR REPLACEMENT WITH RPO CODE ZRX/EXTREME W/ CF5 REMOVAL PROCEDURE 1. With a medium flat-bladed tool, remove the service cover. 2. Remove the motor/actuator trim cover screw (2). 3. Lower the trim cover (1) and remove the sunroof switch (4). 4. Disconnect the electrical connector from the motor (3). 5. Remove the 2 outer motor/actuator screws (2). Page 8093 Removal Procedure 1. Remove the rear seat floor filler trim panels. 2. Remove the body side trim panels, as necessary. 3. Remove the jack from the vehicle. 4. Remove the endgate or the liftgate door sill trim plate. 5. Remove the bolts that retain the cargo tie down hooks to the floor. 6. Remove the cargo tie down hooks. 7. Remove the rear carpet or the mat from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the rear carpet or the mat to the vehicle. Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the air cleaner outlet duct. 2. Partially drain the cooling system. 3. Remove the radiator inlet hose from the radiator support. 4. Using the J 38185, reposition the radiator inlet hose clamp from the radiator. 5. Reposition the radiator inlet hose from the radiator. 6. Using the J 38185, reposition the radiator inlet hose clamp from the coolant outlet. 7. Reposition the radiator inlet hose from the coolant outlet. 8. Remove the radiator inlet hose. Installation Procedure Page 5895 Page 1495 Installation Procedure Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. 1. Install the valve pushrods. Important: Be sure that the arrow on the valve rocker arm support is in the up position. 2. Install the valve rocker arm supports. 3. Apply prelude GM P/N 12345501 (Canadian P/N 992704) or equivalent to the following valve rocker arm contact surfaces: ^ Valve pushrod socket (1) ^ Roller pivot (2) ^ Valve stem tip (3) Page 9224 Engine Harness Rear (4.3L) Page 4650 7. Install the boot seals into the caliper housing bores using the J8092 and the J43885. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear Disassembly Procedure 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 3. Remove the piston from the caliper bore. 4. Remove the boot from the caliper bore. Do not scratch the housing bore. Page 2419 Disclaimer Page 9395 Abbreviations And Meanings - Part 8 Page 2281 Heated Oxygen Sensor (HO2S), Bank 1 Sensor 2 Page 298 7. Position the cover to the sunroof panel window garnish molding (3). IMPORTANT: Ensure the wires are positioned away from the trim cover attachment screw. 8. Install the motor/actuator trim cover screw (2). Tighten Tighten the screw to 1.5 N.m (13 lb in). 9. Install the motor/actuator service cover. Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the 2 halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery. NOTE: Refer to Handling ESD Sensitive Parts Notice in Service Precautions. INSTALLATION PROCEDURE 1. Install the battery with the positive (+) side up. Use one 3 V CR2032 battery (or the equivalent). 2. Ensure that the seal is in position. Align the 2 halves of the case and snap the two halves together. 3. Resynchronize the transmitter. Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Control Module C1 Page 177 Powertrain Control Module (PCM) Connector C1 Part 3 Page 5027 Abbreviations And Meanings - Part 16 Page 2194 Floor Pedals Drive Belt Idler Pulley Replacement - Right Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Right Drive Belt Idler Pulley Replacement - Right Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt idler pulley bolt. 3. Remove the drive belt idler pulley. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the drive belt idler pulley and bolt to the generator mounting bracket. Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Shift Cable: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 1624 Drive Belt Falls Off Diagnosis Step 1 - 12 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The number(s) refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked may will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Page 744 Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 8691 Abbreviations And Meanings - Part 11 Page 7679 Abbreviations And Meanings - Part 7 Page 7687 Abbreviations And Meanings - Part 15 Page 8343 WA813K/89 - WA817K/63 Diagrams Power Seat Motor Position Sensor: Diagrams Seat Front Vertical Position Sensor - Driver (w/ Memory) Page 444 Camshaft Position (CMP) Sensor Page 6874 5. Install the upper seat belt anchor plate and bolt to the vehicle. Tighten Tighten the upper seat belt anchor plate bolt to 70 N.m (52 lb ft). 6. Install the upper seat belt anchor bolt cover. 7. Install the lower seat belt anchor plate to the rear seat bolt. 8. Install the rear seat assembly. Page 2994 7. Remove the vent valve (1) from the bracket (2). INSTALLATION PROCEDURE 1. Slide the vent valve (1) onto the bracket (2). 2. Connect the vent hose (3). 3. Connect the vent valve electrical connector. 4. Install the shield (2) to the fuel tank shield (3) with the retainers (1). 5. Raise the spare tire, underbody mounted spare tire only. 6. Lower the vehicle. Page 608 Disclaimer Page 1068 1. Install the power steering gear pressure hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the power steering gear pressure hose to the power steering gear. Tighten the power steering gear pressure hose to the power steering gear to 30 Nm (22 ft. lbs.). 3. Install the air cleaner assembly. 4. Raise the vehicle. 5. Connect the power steering gear pressure hose to the power steering pump. Tighten the power steering gear pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). 6. Remove the drain pan from under the vehicle. 7. Install the steering linkage shield, if equipped. 8. Lower the vehicle. 9. Bleed the power steering system. Page 8454 Sunroof / Moonroof Switch: Description and Operation SUNROOF SWITCH The sunroof switch has three positions: - Close - Off, in rest position - Open Pressing the forward portion of the sunroof switch will slide the sunroof window to the close position. Pressing the rearward portion of the sunroof switch will raise the rear edge of the sunroof window and then will move the sunroof window from the close position to the full open position, unless the switch is released. Page 8854 7. Install the filler plate using the 2 push-pin fasteners. 8. Secure the splash shield to the rear step panel using the 3 push-pin fasteners. 9. Tighten the 3 step panel to rear bracket screws from Step 6. Tighten Tighten the screws to 9.0 N.m (6.6 lb ft). 10. Install the step pad to the step panel using the following steps: 10.1. Insert the locator pin on the pad into the hole in the panel. 10.2. Press the retainer tabs on the pad into the holes in the panel. Locations Engine, LR Page 9479 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(r) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Locations Relay Block - Body Relays, Except Envoy Page 6061 Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Page 6081 Abbreviations And Meanings - Part 4 Page 2632 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to A/C Refrigerant Filter Installation Refrigerant Filter: Service and Repair A/C Refrigerant Filter Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT:The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the PCM. 2. Remove the engine coolant reservoir. 3. Loosen the accumulator nut at the evaporator. 4. Reposition the accumulator (4) in order to gain access to the evaporator tube (1). 5. Measure 100 mm (4 in) from the bend after the high side access port and mark the location. 6. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. 7. Using a tubing cutter, cut the marked section of the evaporator tube (1). IMPORTANT:Do not allow metal burrs to enter the tube during cutting or when removing the burrs. 8. Remove the burrs from the evaporator tube (1). 9. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). 10. Push the nuts (4), and the ferrules (3) over each of the evaporator tube halves. IMPORTANT:DO NOT install the O-rings (2) in this step. 11. Install the ferrules (3) with the small end toward the nut (4). Page 8497 Sunroof Control Module C2 Page 4075 12. Install the TCC solenoid with a new O-ring seal to the valve body. 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 9384 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 2462 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at top dead center of the compression stroke. IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning number 1 piston at top dead center (TDC). With the piston on the compression stroke and at top dead center, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1) or V8 engine (2). - The alignment will not be exact. - If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when the gear is installed in the distributor. NOTE: Refer to Distributor Driven Gear Can Be Installed in Multiple Positions Notice in Service Precautions. Page 373 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the sensor and Distributor before removal. Do not allow debris to enter the engine. 1. Remove the distributor. 2. Disconnect the engine oil pressure sensor electrical connector. 3. Remove the engine oil pressure sensor using the J 41712. Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 4. Remove the engine oil pressure sensor fitting, if necessary. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the fitting and/or the engine oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. Page 9382 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 123 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector. 4. Remove the 3 nuts that retain the cruise control module to the mounting bracket studs. 5. Remove the cruise control module from the mounting bracket. 6. Remove the 3 screws that retain the mounting bracket to the cowl panel. INSTALLATION PROCEDURE 1. Install the mounting bracket to the cowl panel with the 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the cruise control module bracket screws to 4.5 N.m (40 lb in). 2. Install the cruise control module to the vehicle. 3. Install the 3 nuts that retain the cruise control module to the mounting bracket. Page 6894 3. Install the driver-side seat belt buckle or buckles to the seat. 4. Install the bolt that retains the driver-side seat belt buckle or buckles to the seat. Tighten Tighten the seat belt buckle or buckles bolt to 70 N.m (52 lb ft). 5. Connect the driver-side seat belt buckle electrical connector. Page 1128 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Front and Rear Grade ......................................................................................................................... .................................................................................................... GL-5 Viscosity ................................ .............................................................................................................................................................. ..................... 80W-90 Page 7638 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Engine Oil Cooler Hose/Pipe Oil Line: Specifications Engine Oil Cooler Hose/Pipe Engine Oil Cooler Pipe Clip Bolt to Oil Pan ........................................................................................................................................... 9 Nm (80 inch lbs.) Engine Oil Cooler Line Clamp Bolt ...................................................................................................................................................... 10 Nm (89 inch lbs.) Engine Oil Cooler Line to Adapter Bolt ................................................................................................................................................... 35 Nm (26 ft. lbs.) Engine Oil Cooler Line to Radiator Connectors ....................................................................................................................................... 31 Nm (23 ft. lbs.) Engine Oil Cooler Lines to Oil Filter Adapter Retaining Bolt .................................................................................................................. 35 Nm (26 ft. lbs.) Page 3125 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE Fuel Meter Body Assembly 1. Remove the upper intake manifold assembly. 2. Remove the fuel pressure regulator retainer clip (13). 3. Pull and twist the fuel pressure regulator (14) in order to remove the fuel pressure regulator from the fuel pressure regulator housing using a shop towel to catch any spilled fuel. 4. Remove the regulator seal lower O-ring (18). 5. Remove the regulator assembly filter (17). 6. Remove the regulator seal upper O-ring (16). 7. Remove the regulator seal backup ring (15). 8. Cover the fuel pressure regulator housing to prevent contamination from entering the fuel system. 9. Discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: If the fuel pressure regulator is to be reinstalled, inspect the filter screen for contamination. If the filter screen is contaminated, replace the regulator. Page 5239 C109 (Body Harness To The 4WAL/SIR Harness) Page 731 Transmission Speed Sensor: Service and Repair NV 3500 Vehicle Speed Sensor (VSS) Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the electrical connector from the vehicle speed sensor. 3. Remove the following parts: ^ The vehicle speed sensor ^ The O-ring seal Installation Procedure 1. Coat a new O-ring seal with a thin film of transmission oil. Notice: Refer to Fastener Notice in Service Precautions. Page 6793 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 9747 Door Lock And Window Switch - Front Passenger C1 Part 2 Door Lock And Window Switch - Front Passenger C2 Page 6452 Page 9875 For vehicles repaired under warranty, use the table. Disclaimer Page 6646 IMPORTANT:Install the shorter screen end of the expansion (orifice) tube into the evaporator first. 2. Coat the new O-ring seal with 525 viscosity refrigerant oil. 3. Install the new O-ring seal. 4. Install the evaporator tube to the evaporator (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the evaporator tube to.............................28 N.m (21 lb ft). 5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings components using the J 39400-A. Specifications Parking Brake Warning Switch: Specifications Park Brake Warning Light Switch Mounting Bolt 35 inch lbs. Page 4231 Important: ^ Ensure that the shift lever is positioned into the mechanical third or fourth gear prior to removal of the shift housing from the transmission. The transmission must remain in this state when the shift housing is removed. ^ Do not disassemble the transmission shift housing. Internal parts for this shift housing are not available. Opening the shift housing voids the warranty. ^ When removing the shift housing from the transmission, use the exposed bolts on the base of the housing. ^ If equipped, remove the 3 console nuts and console. 1. Remove the shift lever from the shift tower. 2. Pull back the carpet to access the screws. 3. Remove the screws securing the boot to the panel. 4. Remove the 4 bolts securing the shift housing to the transmission. 5. Remove the shift housing. Installation Procedure Page 6638 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 8752 Seat Adjuster Switch - Front Passenger C1 (w/ 8-Way, w/o Memory) Part 2 Page 9513 Abbreviations And Meanings - Part 9 Page 8695 Abbreviations And Meanings - Part 15 Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The Malfunction Indicator Lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A Diagnostic Trouble Code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 5753 C300 (Dome Lamp Harness To Sunroof Harness) Page 7976 Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Rear Compartment Lid Tools Required J 34940 Rivet Gun Removal Procedure 1. Remove the endgate cover. 2. Disconnect the electrical connectors, as needed. 3. Drill out the rivets that retain the endgate window release actuator to the endgate cover. 4. Remove the endgate window release actuator from the endgate cover. Installation Procedure 1. Install the endgate window release actuator to the endgate cover. 2. Install the rivets that retain the endgate window release actuator to the endgate cover using the J 34940. 3. Connect the electrical connectors, as needed. 4. Install the endgate cover. Page 8657 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs Page 2235 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at Top Dead Center (TDC). Locations Coolant Temperature Sensor/Switch (For Computer): Locations Left Side Of The Engine Components (4.3L) Page 7973 Liftgate (Utility) Page 3425 Spark Plug: Specifications Spark Plug Torque Used heads 15 Nm 11 lb. ft. New aluminum heads 20 Nm 15 lb. ft. New iron heads 30 Nm 22 lb. ft. Page 3061 1. Install the MAF sensor to the air cleaner outlet duct and the air cleaner cover. IMPORTANT: The embossed arrow on the MAF sensor indicates the proper air flow direction. The arrow must point towards the engine. 2. Secure the air cleaner cover and outlet duct to the MAF sensor. 3. Connect the MAF sensor harness connector. Page 6195 Suspension Strut / Shock Absorber: Specifications Shock Absorber Lower Nut (4-Door Utility) 74 ft. lbs. Shock Absorber Lower Nut (Pickups and 2-Door Utility) 62 ft. lbs. Shock Absorber Upper Bolts 18 ft. lbs. Page 5515 METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 3185 Steps 6-9 Page 7662 Arrows And Symbols Uses various symbols in order to describe different service operations Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 794 Abbreviations And Meanings - Part 3 Brake Drum Replacement Brake Drum: Service and Repair Brake Drum Replacement Brake Drum Replacement Removal Procedure 1. Raise the vehicle and support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and the wheel from the vehicle. 3. Mark the relationship of the rear brake drum to the axle for reference. 4. Remove the rear brake drum retainers if present. 5. Remove the rear brake drum from the vehicle. Installation Procedure 1. Locate the relationship mark and install the brake drum to the axle. 2. Install the tire and the wheel. 3. Adjust the rear brakes. 4. Remove the safety stands. Lower the vehicle. Locations Inflatable Restraint Steering Wheel Module/Horn Pad Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Page 9342 Page 1770 8. Install the upper intake manifold onto the lower intake manifold. 9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the upper intake manifold attaching studs. 10.1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 inch lbs.). 10.2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 inch lbs.). 11. Install the fuel lines to the fuel meter body assembly. 12. Install the Evaporative Emission (EVAP) canister purge solenoid valve. 13. Install the bracket for the engine wiring harness on the lower intake manifold stud. 14. Install the engine wiring harness bracket nut. Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.). Page 1852 Steps 9-12 Specifications Balance Shaft: Service and Repair Balance Shaft Replacement ^ Tools Required J 8092 Universal Driver Handle - J 36660-A Electronic Torque Angle Meter - J 36996 Balance Shaft Installer Removal Procedure 1. Remove the radiator. 2. Remove the A/C condenser. 3. Remove the valve lifter pushrod guide. 4. Remove the timing chain and camshaft sprockets. 5. Remove the balance shaft drive gear. Important: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt. 6. Remove the balance shaft driven gear bolt from the balance shaft. 6.1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 6.2. Remove the balance shaft bolt. 6.3. Remove the wrench from the balance shaft. 7. Remove the balance shaft driven gear from the balance shaft. Page 8112 Console: Service and Repair Console Replacement - Front Floor (Non-Full Length) Console Replacement - Front Floor (Non-Full Length) Removal Procedure 1. For manual transmission only, remove the shift control lever. Refer to Control Lever and/or Boot Replacement in Manual Transmission - NV 1500 or to Control Lever and/or Boot Replacement in Manual Transmission - NV 3500. 2. Remove the console from the floor. Pull up on the console in order to release the retainer clips. Installation Procedure 1. Use care when installing the console so the clips do not bend. 2. install the console to the floor. 3. For manual transmission only, install the shift lever. Refer to Control Lever and/or Boot Replacement in Manual Transmission - NV 1500 or to Control Lever and/or Boot Replacement in Manual Transmission - NV 3500. Page 8192 3. Install one short front screw (1) and install one long rear screw in order to hold the garnish molding (3) in position. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the remaining screws including the one other short screw next to the motor/actuator. Tighten the screws to 1.5 N.m (13 lb in). 5. Install the 8 sunroof panel window garnish molding screw covers. Page 8898 Sunroof / Moonroof Weatherstrip: Removal and Replacement Sunroof Seal/Molding Replacement (ZRX/EXTREME w/ CF5) Removal Procedure 1. Remove the sunroof window. 2. Remove the seal (2) from the front of the upper frame by pulling upward on the seal. 3. Finish removing the seal from the rear of the mainframe. 4. Completely clean the channel in the mainframe of silicone adhesive and any other debris. A nylon glazing stick or a soft wire brush would be helpful in removing the silicone. Installation Procedure 1. Apply black, non-corrosive silicone adhesive under the entire outside edge of the seal. 2. Insert the new window seal by pressing the seal into the mainframe channel (3). Use a roller-type tool on the seal to aid in the installation of the seal into the channel. 3. Install the sunroof window. 4. Fully close the sunroof and wait 4-6 hours for the silicone to dry. 5. Visually inspect the window and seal in the full open and closed positions. 6. Open the sunroof. 7. Inspect the seal for high spots, correct if needed. Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Page 7305 Registered And Non-Registered Trademarks - Part 4 Page 4574 4. Install the axle shaft. 5. Adjust the park brake shoe (1). 6. Install the brake rotor. 7. Install the tire and wheel assembly. 8. Lower vehicle. Refer to Vehicle Lifting. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9-10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Adjust park brake cable. Brake Rotor Refinishing Brake Rotor Refinishing Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Page 9406 Abbreviations And Meanings - Part 19 Page 3948 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Page 3336 Engine Generator And Starter Page 4648 5. Using J26267, install the front caliper piston boot.. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bleeder valve. Tighten the bleeder valve to 12 Nm (110 inch lbs.). Brake Caliper Overhaul - Front (Dual Piston) Brake Caliper Overhaul - Front (Dual Piston) Tools Required ^ J8092 Driver Handle ^ J43885 Boot Seal Installer Disassembly Procedure 1. Drain all the brake fluid from the caliper. 2. Install a piece of wood or shop towels between the piston and the inside of the brake caliper. Caution: Refer to Eye Protection Caution in Service Precautions. Notice: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 379-427 kPa (55-62 psi) Page 1469 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8 - 11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8 - 11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. ^ Normal The compression builds up quickly and evenly to the specified compression. ^ Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. ^ Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 8650 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Locations Floor Pedals Page 6155 Tighten the transmission mount to the transmission support stud nut to 45 N.m (33 lb ft). 9. Connect the transmission wiring harness to the transmission support, if necessary. 10. Remove the transmission jack from the transmission. 11. Lower the vehicle. Page 7823 4. Install the upper latch striker cover. Page 5344 C303 (Power Seat Harness, RH To Power Recliner Harness, RH) (w/ Power Seats, Non-Memory) Page 2944 Transfer Case (With RPO Code NP8) Harness Routing View A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 7890 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Remove the side rear door trim panel. 2. Remove the staples that secure the sealing strip to the trim panel. 3. Remove the sealing strip. Installation Procedure 1. Position the sealing strip on the trim panel. 2. Install the sealing strip to the trim panel using the original staples or a heavy-duty staple gun. 3. Install the side rear door trim panel. Page 2957 Park Neutral Position (PNP) Switch Page 2398 Steps 4-7 Page 5734 C203 (Body Harness To IP Harness) Part 8 Page 655 Inflatable Restraint Front End Discriminating Sensor - Right A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 7254 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 6094 Abbreviations And Meanings - Part 17 Page 2662 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9624 Abbreviations And Meanings - Part 5 Page 6187 4. Raise the axle support so that there is a distance of 164 - 176 mm (6.46 - 6.94 inch) between the axle tube and the metal surface of the bumper bracket (1). Notice: Refer to Fastener Notice in Service Precautions. 5. Tighten the spring shackle mounting nuts. Tighten the spring shackle mounting nuts to 122 Nm (89 ft. lbs.). 6. Remove rear axle support. 7. Raise exhaust system and connect rear exhaust hangers, if necessary. 8. Install the spare tire, if necessary. 9. Install the EVAP canister (2-door utilities only), if necessary. 10. Install the fuel tank (2-door utilities only). 11. Lower the vehicle. Page 9372 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. Page 7947 2. Install the primary latch support bracket to the vehicle. 3. Install the bolts that retain the primary latch support bracket to the radiator support. Tighten the primary latch support bracket to the radiator support bolts to 25 N.m (18 lb ft). 4. Install the primary hood latch assembly. 5. Install the radiator grille. 6. Close the hood. C100 - C119 Multiple Junction Connector: Diagrams C100 - C119 C100 (Heated Oxygen Sensor Harness To Engine Harness) Part 1 Page 8335 WA605H/45 - WA711J/58 Page 3648 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Page 8185 2. Remove the motor/actuator trim cover screw (2). 3. Lower the motor/actuator trim cover and remove the sunroof switch (4) from the cover (5). 4. Remove the 2 short screws (1, 2) from the sunroof panel window garnish molding. 5. Remove the 8 screw covers (3) from the lower sunroof panel window garnish molding. Power Steering Pump Flow Control Valve Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Replacement Off Vehicle (CB Series) Power Steering Pump Flow Control Valve Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Remove the connector and fitting assembly (4). 2. Remove the O-ring seal (3). 3. Remove the control valve assembly (3) and the flow control spring (2) from the pump housing assembly (1). Assembly Procedure 1. Install the flow control spring (2) to the pump housing assembly (1). 2. Install the control valve assembly (3) to the flow control spring (2). Page 9601 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut.